Documentos de Académico
Documentos de Profesional
Documentos de Cultura
FOR
MOUNDED STORAGE FACILITY
Description
40 or
2.
Tolerance
3.
Inspection
4.
Impact Testing
5.
Ultrasonic Testing
6.
Heat Treatment
: Normalized
7.
: 80,000 psi.
8.
9.
Supplementary Requirement
a) The plates shall be free of scales and rolled in the direction of length specification
and shall be supplied in the normalized condition. Accelerated cooling by liquid
quenching or other means is not permitted. Plates shall be ordered with testing of
sample for mechanical properties after simulation.
b) The plates shall be supplied with gas/sheared edges with tolerance as per SA 20
latest. Manual gas cutting is not acceptable. Tolerance on thickness shall be
positive only.
c) All the plates shall be supplied in normalized condition.
d) The plates shall be free from injurious defects and shall have work-man like finish
reconditioning/ repair of plates by welding is not permitted.
e) One product analysis of each heat shall be done as per relevant BS code on the
entire surface of the plate with a square grid of 200 mm. UST shall be done after
heat treatment and results recorded in the test certificates.
f)
10.
A) All Tests should be carried out in the presence of the Third Party Inspection
Agency and shall be certified and stamped on each plate ON BOTH ENDS.
B) MARKING: The plates shall be marked with the No. of relevant Standard and
approximate Grade No.
The Third Party Inspection at the BQ Plate suppliers Work shall be arranged
by the tenderer & the rates quoted shall be inclusive of this Inspection.
However, The TP Stampings on the Plates & material Test Certificates put at
the manufacturers works shall also be inspected by TPIA. Approved TPIA for
inspection of Steel Plates at suppliers works are M/s Lloyds / M/s Bureau
Veritas / M/s IRS.
D) Vendor to carry out FEM Analysis for the Plates supplied. This is an essential
requirement.
E) Manufacturers Test Certificate in 3 sets to be dispatched immediately after TPIA
clears the goods from their side.
F) Production Test Coupon requirement should be as follows:
i.
Note:
i.
The bidder must specify the specifications and make of the BQ steel plates
offered by him in the Unpriced Bid.
ii. The rates quoted for Supply of Steel Plate should be inclusive of all above
requirements.
VESSEL
1. Storage Capacity of LPG
: 10 MT each
3. Density of LPG
: 0.525 gm/cc
de
6. Design Temperature
: - 27 C to + 55 C
: As per code
8. Radiography
9. Corrosion Allowance
: 1.5 mm
: Required
: Required
:1
: As per requirement.
Notes:
1.
2.
FEM Analysis shall be conducted for the Vessel to assess the stresses in the vessel
& stiffener for various loading conditions & report shall be submitted to
TPIA/HPCL for approval.
3.
Stiffeners shall be provided as per the design requirements. The detailed design
for stiffeners shall be submitted to HPCL for prior approval.
4.
As the bottom 120 deg. Area is not accessible at hydro test, the weld joints in this
region shall be ultrasonically tested followed by DP testing after hydro test.
5.
All ASTM Pressure parts shall meet the Design Code Requirements for Impact
testing as per app. D & Cl. 2.3.2 of PD 5500 (latest edition) or equivalent. The
requirement of OISD 150 shall also be incorporated.
6.
2.0
MATERIAL SPECIFICATIONS:
3.0
1.
2.
Nozzles
: SA 333 Gr. 6
3.
Flanges
4.
Couplings
5.
6.
Bolts/Nuts
Gaskets
Nozzles:
Following Nozzles shall be provided by the Vendor on each Pressure Vessel. A
sleeve structure made of glass reinforced epoxy or un-plasticised polyvinyl chloride
shall be provided around nozzles and manholes in line with EEMUA
recommendations. Final orientation of all Nozzles will be given by HPCL at the
time of approval of Fabrication drawings. The Liquid Inlet/Outlet Nozzle shall
extend upto 3 m from the face of vessels & shall have no flange Joint except at the
end. It shall be adequately supported & shall be stress relieved & Hydro tested.
All Nozzles should be provided with SA 350 Gr. LF2, 300 lbs. RF blind Flanges.
1.
: 1 no.
2.
: 1 no.
3.
: 2 no.
4.
: 2 no.
5.
6.
: 1 no.
7.
: 2 nos.
8.
: 2 no.
(Party to design Safety Valve & Nozzle & submit calculations for the same)
9.
: 1 no.
10.
12.
: 1 no
13.
4.0
: As Required.
MISC. REQUIREMENTS:
1.
: As required
: 1 no. per Vessel.
In addition to providing the name plate, the following details are to be punched on
the manhole flange ring.
1.
2.
Design code
Design pressure
3.
4.
5.
6.
7.
Test pressure
Date of first test
Inspected by
Certificate number
Drawing number
One no. 50 NB matching flange of material SA 350 Gr. LF2 and rating conforming
to ANSI B-16.5 Class 300 R/F.
1.2
All wetted parts like displacer, wire, spring etc. shall be made up of stainless steel
AISI 316.
1.3
Power supply
1.4
: 230 V 50 HZ
Note :
Vendor will be required to import above Level switch through their own import
license and at their own cost. No assistance in import of this item will be rendered
by HPCL to the Vendor. However, Vendor is required to indicate in their quotation as
to how Level Switch will be arranged by them.
DATA SHEET
LEVEL SWITCH-(HIGH LEVEL ALARM SWITCH)
Make
Qty.
Specific gravity
: 0.525
Liquid
: LPG
Type
: Displacer type
Construction
& Enclosure
Flange
Op. Temperature
Pressure
: 17 Kg./sq.cm.gauge
Test pressure
: 22.5 Kg./sq.cm.gauge
Alarm type
: H (1 point alarm)
Conduit size
Power source
: 230 V / 50 Hz.
Transmitter
Switch type
: SPDT
Accuracy
:*
SERVICE
: LPG VAPOUR
QUANTITY
: FULL NOZZLE
CONVENTIONAL/BELLOWS
: CONVENTIONAL
BONNET OPEN/CLOSED
SIZE-INLET/OUTLET
: VTS AS REQUIRED
: 300# /150#
TYPE OF FACING
: RF SERRATED
BODY/CYLINDER
SEAT DISC
: SS 316
SPRING
: CS,CD PLATED
NOZZLE/GUIDE RING
: SS 316
CAP SCREWED/BOLTED
LEVER PLAIN/PACKED
:
: NOT REQUIRED
TEST GAG
: NOT REQUIRED
CODE
CALCULATION CODE
: API 520
RELIEVES TO
: ATMOSPHERE
: LPG VAPOUR
: 1.90
MOLECULAR WT
: 50.00
: 2-11(GAUGE)
: 14.5 (GAUGE)
OPERATING TEMPERATURE
: 3-45 DEG.C
RELIEVING TEMP
: 55 DEG. C
BACK PRESSURE
: ATMOSPHERIC
: 21 PERCENT
CP/CV
: 1.12
VISCOCITY FACTOR
: NIL
RELIEVING CAPACITY
: VTS
SELECTED AREA
: VTS
ORIFICE DESIGN
: VTS
MISCELLANEOUS:
1. VENT PIPES
2.
NOTE:
(a)
VENDOR SHALL INDICATE THE MAKE OF THE SRV IN THE UNPRICED BID.
(b)
(c)
Type
True, ON-LINE.
b)
Pure Sine-wave
c)
230 V 30%
d)
Output
220 V 2%
e)
Input Frequency
50 Hz 5 Hz
f)
Output Frequency
50 Hz 1 Hz
g)
Backup time
30 Minutes
h)
Battery type/make
i)
Qty/Capacity of UPS
The UPS is intended for all instruments of 2 x 10 MT mounded LPG storage vessels, ROVs
& High level alarm switches.
j)
Makes :
a)
Type
ON - LINE
b)
Pure Sine-wave
c)
230 V 30%
d)
Output
220 V 2%
e)
Input Frequency
50 Hz 5 Hz
f)
Output Frequency
50 Hz 1 Hz
g)
Backup time
30 Minutes
h)
Battery type/make
i)
Qty/Capacity of UPS
Makes
SCOPE OF WORK
This specification governs the minimum requirements for materials (coating as well
as surface preparation prior to coating), equipment, coating application, inspection,
repair, handling and all other aspects of external corrosion protection of Mounded
Bullets for bulk storage of the liquifiable (hazardous) gases under pressure.
It is envisaged that the Polyurethane coating ( 100% solids, high build, elastomeric)
on the external surface of the mounded bullets shall provide a hard, tough, high
electrical resistance (for corrosion prevention in conjunction with cathodic protection
system) surface with outstanding adhesion and impact resistance to protect against
damage during the process of mounding (compaction of graded sand followed by
earth cover). The coating system shall be suitable for service temperatures between
minimum -55 C and ambient + 55 C (although these temperatures may not be
normally achieved/ encountered) in service. Also very high levels of chlorides &
sulphates, particularly in coastal installations, should be withstood by the coating
during entire design life span.
In mounded bullets, with internal pressures the unfired shell areas widen more than
the ring stiffened region. The coating system shall withstand, without damage during
the entire service life span, the constraint developed thus producing bending
moments in the mounded bullets in longitudinal direction, the maximum of which
occur/ are likely to occur in the plane of the ring stiffener.
The work to include furnishing all labour (skilled & unskilled), materials, tools &
tackles, equipment & performance of all operations and incidentals necessary for
coating handling, storing and transporting of coated bullets or part thereof. The
coating operations will have to be carried out in narrow space around the mounded
bullet prior to graded sand filling and compaction around the fabricated bullet.
The steel surface preparation prior to actual commencement of coating shall conform
to
STEEL
STRUCTURE
PAINTING
COUNCIL-:
SURFACE
PREPARATION
SPECIFICATION: SSPC-SP10
Removal of all equipment and excess materials from site, following completion of
coating operations is included in the scope of work.
Prior approval from owner/ consultant shall be obtained by the coating applicator for
any deviations from the requirements of this specification and/ or the standards
referred therein.
2.
REFERENCE DOCUMENTS:
NACE TM-01-7
NACE TM-01-75
3.
GENERAL REQUIREMENTS:
The applicator shall submit for owner/ consultants approval, coating procedure
including quality assurance (QA) & quality control (QC) methodology, prior to
commencement of coating of the bullets. Only duly approved methodology shall be
followed in coating application.
The applicator shall provide standard equipment for coating works, no improvised
equipment will be accepted/ allowed.
The applicator shall supply all coating materials required as per this specification &
provide test data/ reports from standard laboratories. The applicator shall also carry
out tests on applied coating for adhesion, film thickness and pinhole/ holiday
detection. The results of these tests shall be through a owner/ consultant approved
laboratory.
Considering logistical and technical aspects, coating of bullets shall be carried out in
the mound
( prior to grade sand filling & compaction) after post weld heat
treatment and hydrostatic testing.
All manpower (skilled , unskilled) shall be applicators responsibility and only
personnel skilled in the coating application shall be deployed by the applicator.
The coating shall be inspected by qualified inspectors. The qualification of inspectors
shall be verified/ approved by owner/ consultant.
The applicator shall provide access during all phases of work to the owner/
consultants and their inspectors. Any expenses incurred by the applicator due to
owner/ consultants inspectors stopping the coating work because it is not being
carried out as per these specifications, shall be borne by the applicator.
All equipment shall be subject to owner/ consultants approval and should be of good
quality, maintained in good operating condition and suitable for use to apply
materials as per this specification.
All cleaning, priming, coating machines shall be preferably equipped with rubber or
wheels overlaid with hard fiber to prevent marking or denting the external surface of
the bullet.
The owner shall provide coating schedules & engineering information including
drawings when available, showing all dimensions, obstructions and access to the
surface area to be coated as well as the calculations of area to be sprayed.
Before, bid submission, the applicators are advised to acclimatize themselves with
site working conditions and owner will permit such visits by applicators.
During surface preparation, any acceptable metal defects detected shall
be
immediately brought to the notice of owner/ consultant and the applicator shall hold
the work on such steel piece till such time as cleared for further action by the owner/
consultant.
Only plural component air less spray system shall be used as per recommendation of
the manufacturer of Primer Polyurethane.
4. SAFE PRACTICES:
High performance spray applied coatings may contain potentially toxic ingredients
and require all (local, state, central) safety regulations to be observed during coating
operations. Proper safety precautions must be observed against recognised safety
hazards even during storage of primer & coating materials at site. Applicable
(statutory, state, local) regulations governing safe handling practices, shall be
enforced.
5. MATERIAL SPECIFICATION
Sr
1
2
3
Property
Tensile Strength
Adhesion(elecometer pull off)
Recoverable Elongation
Value
15 N/ sqmm (Min)
8 N/ sqmm (Min)
50% Min. At 25 C
Test Method
ASTM-D638
ASTM-D4541
ASTM-D638
4
5
6
7
Sr
8
9
10
11
50 (Min)
0.5 gms/24hr/sqm (max.)
-55 C to +55 C
No Effect
Property
Nom. Film thickness(film build)
Value
1000 micron. (unless otherwise
specified)
2.3*105 gms. Cms (min)
Impact Resistance
13
Tear Strength
Abrasion Resistance (Taber
Abraser H-10 wheel 1000 gm
1000 cycles)
Cathodic Disbondment (-1.5 v 7075 F 30 days)
Flexibility at 25 C
14
Accelerated Weathering
12
SHORE D
ASTM-E96
ASTM-B117-73
Test Method
ASTM G-14 on
steel pipe
ASTM D-624
ASTM-D-4060
ASTM D 1737
ASTM G-23
PRIMER
The type of primer used shall be as per coating manufacturers specifications
a) For areas not to be cathodically protected : Polyvinyl Butryl (wash) type
b) For areas to be cathodically protected
: Aluminium filled moisture cured
Urethane Primer or two (2) component chemical cured Urethane Primer
Single package moisture-cured Urethane primers containing non-leafing Aluminium
pigmented, are fast curing, chemical & corrosion resistant and eliminate the mixing &
pot life limitation of two pack materials.
The primer shall have following characteristics;
Flash Point: 28 C TCC
Coverage:
etc.)
Shelf Life : Six (6) months
Drying time : at 25 C
To touch
To handle
To recant
Clean up :
Toluene (immediately)
30 mts
45 mts
4 hours
6. SURFACE PREPARATION:
Although, Elastomeric 100% solids Polyurethane coating material has excellent
Corrosion and Erosion resistant properties, it must however, be considered part of an
engineered system which includes adequate/ appropriate surface preparation. It is
axiomatic in protective coating work that the performance of most appropriately
chosen coating will be no better than the surface preparation. Accordingly, the
surface shall be blast cleaned as follows;
The external surface of bullets (or part thereof) shall be blast cleaned to SSPC-SP10
specification near white blast cleaning with 2-3 Mil anchor profile (or else conform to
SIS Gr Sa 2-1/2 Specifications)
Near white blast cleaned surface finish is defined as one from which all Oil , grease,
dirt mill scale, rust, corrosion products, oxides, paints or other foreign matter have
been completely removed from the surface.
The abrasive shall not be reused as this could be detrimental to the surface.
Dry sand blasting using compressed air blast nozzles and dry sand of a maximum
particle size not larger than that passing through a 16 mesh screen US Sieve Series
shall only be used.
Grit blasting shall be using compressed air blast nozzles & crushed grit made of cast
iron, malleable iron, steel or synthetic agents other than sand of a maximum particle
size no longer than passing through a 16 mesh screen US Sieve Series. The largest
commercial grade of metal grit permitted by this specification is SAE No. G-25
abrasive material.
Closed re-circulating nozzle blasting using compressed air, vacuum and any of the
preceding abrasive may be used.
The blasted surface shall be brushed with clean brushes made of hair, bristle or fiber
or else blown off with compressed air (from which detrimental oil & water have been
removed) or cleaned by vacuum for the purpose of removing any traces or blast
products from the surface and also for removal of abrasives from pockets & corners.
Blast cleaning operation shall be done in such a manner that no damage is done to
partially or entirely completed portions of the bullet.
If any rust is formed on Bullet (external surface) after Blast Cleaning, the surface shall
be re-blast cleaned before painting.
The blast cleaned surface shall be examined for any traces of oil, grease or smudges.
If present, these shall be removed as outlined in SSPC-SP1-63 specification.
The height of profile of the Anchor pattern product on the surface shall be 50
microns. The height of Anchor pattern to be determined by an Elcometer 123 or
equivalent surface profile gauge. The average reading from ten (10) randomly
selected areas shall constitute the height of the profile. The profile measurement to
be done on flat (with out curvature) areas only.
The blast cleaned surface should be further treated or primed preferably within 24
hours after blast cleaning but in any event before any visible or detrimental rusting
occurs.
All above operations shall be witnessed by & certified by owner/ consultants
inspector.
7. PRIMING
Measure humidity (using PSYCHROMETER) to ensure Dew Point is at aleast 3 C
below the ambient temperature. Under controlled conditions, heating steel surface
may be resorted, to eliminate the condensation problems.
Two component chemicals cure urethane primer shall be sprayed onto the cleaned
surface in a fog coat as thinly as possible (approximately 1 Mil) so as to tint but not
mask the colour of the substrate. The primer on application shall be free from runs &
drips. The primed surface shall be protected so that it will not come in contact with
rain, Mist, Dust or other foreign substances until completely hardened & the Urethane
top coat has been applied.
The Urethane top coat shall be applied before the Prime Coat has completely cured
not less than two (2) hours, nor more than five (5) days after the prime coat has been
applied. However, the Prime Coat at the time of Urethane application, should be hard
and not tacky.
8. COATING
Equipment for spray application shall be plural component Airless spray system
(Graco Hydra Cat 45:1 or equivalent)
Pressure produced at Tip
Tip Size
Temperature
Resin
Activator
50 C - 60 C
10 C - 30 C
Standard instructions from the Manufacturer shall be followed for Spray, material
handling & storage. Always, dry nitrogen (gas) blanket over material shall be
maintained.
Nominal thickness of 100% solids elastomeric urethane shall be 40 Mils (1,000
micro) unless otherwise specified. The finished polyurethane shall be generally
smooth & free of sharp protuberances. A minor amount of sags, dimpling &
curtaining, which otherwise meets specifications requirement shall however be not
considered as cause for rejection.
Before actual coating application on the bullet surface, a test patch shall be applied &
inspected for Runs, drips & Gel time as well as Tack free time. In case of doubt,
Adhesion test shall be carried out.
Unit Repeat Area is calculated along with the Material volume in counter numbers
(counters are attached on the units that measure the volume of materials dispensed),
approximate speed and number of passes. Spray apply requisite thickness in multiple
passes in single application keeping spray gun perpendicular to the substrate. If the
surface is large enough to require more than one day for coating, the edges of the
coated area shall be feathered and roughened with a grinding tool for over spraying
and primed.
Skips, if any, holidays, detected should be repaired with 100% solids Elastomer
Urethane hand mix kit or equivalent after the edges are roughened.
9. INSPECTION
All work under this specification shall be subject to Inspection by the owner/
consultants Inspector. All part of the work shall be accessible to the owner/
consultants inspector. The applicator shall correct any defective work indicated by
the Inspector.
During coating application the wet film thickness shall be measured using Nordson or
equivalent wet film gauge as per ASTM D4414. The dry film thickness shall be
checked with a magnetic mil gauge (by De Flesko or equivalent). The coating shall be
checked for Holidays using Tinkor & Rasor (USA) Holiday detector or equivalent. Due
caution shall be taken not to use detector voltage exceeding di-electric strength of the
coating (400 V/Mil) to avoid damage to the coating.
Pull off Adhesion to steel shall be measured using Elecometer adhesion tester as per
ASTM D 4541 using a Aluminium dolly attached to the coating & a perpendicular
force applied to the dolly. Average reading from three (3) randomly selected spots
shall be at least 8 N/sqmm. Adhesion test shall be carried out on fully cured coating
(7 days at 25 C) & on flat (without curvature) test area.
Applicator shall supply certificate from the coating manufacturer that the material
used (with batch numbers) are free from manufacturing defects & will meet all
performance criteria when properly applied as given in this specifications.
All above test shall be witnessed & certified by owner/ consultants inspector.
Inspection and Testing
All painting materials including primers and thinners for application shall be procured
directly from manufacturers as per specifications and shall be accompanied by
manufacturers test certificates. Paint formulations without certificates are not
applicable.
10. QUALITY ASSURANCE
The contractor shall guarantee that the chemical and physical properties of paint
materials used are in accordance with the specifications contained herein/to be
provided
during
execution
of
work.
GENERAL
The cathodic protection system shall be designed as per latest specifications
and industry standards and the same shall be executed only thru expert
agencies with prior experience of design and providing of CP system for
mounded LPG storage vessels in India. The decision of HPCL with respect to the
design of the CP system shall be final and binding on the contractor.
The impressed current cathodic protection system should provide a uniform
cathodic current density to the target bullet structure in order to maintain the steel
at a potential between -0.85 V and -1.5 V relative to a Cu/CuS04 reference
electrode.
Steel potential needs to be greater than -0.85 V to avoid corrosion and less than 1.5V to avoid excessive hydrogen evolution which Induces hydrogen embitterment
of high carbon steels used in the fabrication of bullet tanks. The protected
structure thus needs to be maintained within a narrow window of 0.65V.
The type of Anode and its positioning relative to the bullet tank has a critical
influence on both achieving the uniform current density and maintaining the
potential of the structure within the -0.85 V to -1.5 V potential range. In addition,
the relative positions of the associated pipes and tanks have to be considered.
2.0
DESIGN BASIS
For designing the system, the following parameters should be considered:
1.
2.
Soil Resistivity
CP current density
3.
4.
5.
6.
(*)
3.0
MONITORING
A suitable Cu/CuSO4 reference cell monitoring system shall be proposed to ensure
that the design parameters can be checked over the lifetime of the CP system.
4.0
5.0
:
:
POTENTIAL CONTROL
The C.P. system shall be provided with automatic potential control. A switch shall
be provided to switch the system between automatic and manual operation.
Automatic reference selector logic with 3 Nos. reference inputs located in the TR
unit will be capable to control the current output such that the structure to soil
potential at the connected reference cell is maintained within 10 millivolts of the
set value.
The potential measuring circuit shall be capable of working with both Cu/CuSO4
and Zinc reference cells. At any given time the system shall be either controlled by
one type of reference cell and other type shall be kept on the standby mode. The
changeover, if required, shall be effected manually at site in the TLP (Test Lead
Point).
The TR unit shall be provided with the following Visual annunciation and alarm:
Under Protection
Over Protection
All Reference Failure
Over Current
A panel-mounted meter to read the bullet-to-soil potential at the selected control reference
cell through a selector switch shall be provided.
6.0
ELECTRICAL SEPARATION
Monolithic Insulating joints of IGP or equivalent approved make shall be provided
on each tank at Manhole covers, gauges and pipe connections to each tank . The
Insulation joint shall be approved by TPIA before erection. Contractor has to get
the design approved by HPCL/TPIA.
7.0
EARTHING
The LPG bullets shall be connected to the central earthing system through two
polarisation cells.
TECHNICAL SPECIFICATIONS
FOR
MECHANICAL WORKS
: CORKEN
Model
: 291
Service
: LPG Transfer
No of Stages
: Single stage
No of cylinders
: 2 Nos
: 25.4 m3/hr
Capacity
: 200 ltrs/min
Speed
: 23.1 bar
Type
Drive
Accessories
Sl
No
1
2
3
4
5
6
Accessories
Size
Ball Valve
Ball Valve
Pressure Gauge(0.300 psig)
Needle Valve
POP Action Valve
4 Way Valve Indicator
40 NB
25 NB
3/8 NB
3/8 NB
NB
25 NB
Rating
minimum #
800
800
6000
6000
6000
800
Quantity
1
2
2
2
2
1
MOTOR
Type
Standard followed
Motor Rating
Motor speed
: 1440 rpm
Construction-mounting
Insulation
: B Class
Duty
: Continuous duty IP 65
CONTROLS
Local LPG Control Panel
: Required
: Required
: Required
: Required
: CORKEN
Type
Model
: Z 2000
Service
: Propane/LPG
Capacity
: 12 m3/hr
NPSH Required
: NIL
Pump speed
: 600 rpm
Head
: 120 psi
: 50 x 50 NB
MATERIAL OF CONSTRUCTION
Case, Heads, rotor, cam, side plate
Bearing Cap
: Gray Iron
Steel Rotor
: Carbon
Shaft
Vanes
: Steel
: Plastic
Relief Valves
: Steel
Bearing
: Cylindrical Roller
Seals
: Mechanical
Speed
: 600 rpm
MOTOR
Type
Standard followed
Motor Rating
: 5 HP
Motor speed
: 1440 rpm
Construction-mounting
Insulation
: B Class
Duty
: Continuous duty IP 65
Make
: Crompton Greaves/Bharat
Bijlee/Siemens
Description
Size
Std
50 NB
3/8NB
3/8 NB
NB
50 NB
50 NB
50 NB
50 NB
Rating
Qty
1
300#
3000#
3000#
3000#
300#
300#
300#
300#
Required
Required
Required
Required
Required
3
2
2
2
1
1
1
1
Inlet Pressure
: 0 -20 kg/sqcm
Outlet Pressure
: 2 kg/sqcm
Flow Rate
Size
: As required
AUDCO Valve
Pressure Gauge
Type
Length of hose
: 3 metres
Material
Flare Line
A flare line is to be provided at the unloading point for flaring of the unloading
hose.
: GASOR 500-L/ANIL
Type
Medium
: Water
VESSEL
BIS 2825 Class 3
Atmospheric for water
30 deg C 80 deg C
5 kg/sqcm for water
100 deg C
Water
filling
7.5
kg/sqcm
COIL/LPG
For LPG ASME B 31.4
6-8 kg/sqcm(g)
30 deg C 80 deg C
14.5 kg/sqcm (g)
100 deg C
19 kg/sqcm
: Required
Capacity
: 500 kg/hr
Size LPG
: Inlet 40 NB
Connections
Power requirement
Outlet 50 NB
Coils
No
Controls
Make
Range
Size
MOC
Type
Electrical Heaters
ESCORTS
-------
------
-----
Control Panel
PROMPT
-------
15
KW
-----
------
Pressure Switch
SWITZER
CC/SS
Solenoid Valve
AVCON
0-16
kg/cm2(
g)
--------
*FLP/
EXP
*FLP/
EXP
BRASS
GP
225 psi
50
NB
6 NB
Pressure Indicator
GLUCK
0-300
psi
10
NB
BRASS
GP
Temperature sensor
GP
15
NB
SS
0-360
mm
0-120
deg C
BRASS
SS
*FLP/
EXP
POP
OFF
TYPE
BOUR
DEN
TYPE
GLASS
TYPE
THER
MOST
ATS
Qt
y
---1
1
1
1
1
1
REQUIRED
2.
The air filter regulator, solenoid valve and quick exhaust valve shall be pre tubed
with control valve. The connection size shall be 3/8" NPT.
3.
All electrical accessories, such as limit switch, solenoid valve should be explosion
proof suitable for (NEC) class 1 DIV 1 Group B,C,D and weather proof to IP65.
4.
The solenoid valves shall be energized under 'normal' process conditions and
suitable for operation on 230 VAC.
5.
6.
Cable entry sizes of solenoid valves and limit switches shall be 1/2" NPT (F).
7.
Wires from solenoid valve shall be terminated inside a flameproof terminal box.
8.
The body material of solenoid valve shall be Brass/ Aluminum alloy/ Stainless
steel.
9.
10.
11.
12.
13.
14.
15.
The actuator shall be AUDCO or imported and the approved manufacturers are
BETTIS (USA), KTM (JAPAN), ROTARK (UK),
BIFFI(ITALY), HYTORQ(UK),
ELOMATIC(HOLLAND), NELES-JAMESBERY
16.
The valve shall be fire safe ball valve with API monogram.
17.
All the electrical accessories such as limit switch, solenoid valve etc., shall be flame
proof and weather proof as per IP 65 and shall have the approval of CCOE.
D. RITES
E. BAX COUNSIL
F. IRS
19. SCOPE OF INSPECTION :
A. Make of components
B. Visual inspection.
C. Dimensional check.
D. Scrutiny of material test certificates.
E. Performance test for ROV/Actuator.
F. Testing of Valve
G. Fire Safe Test certificate
20.. OPERATING CONDITIONS
SERVICE
SP. GRAVITY
LPG LIQUID
LPG VAPOUR
0.525
UNITS : FLOW/PRESSURE
CU.M./HR.
KG/SQ. CM.
CLOSURE TIME
INLET PRESSURE(MAX)
12KG/SQ. CM.
MAX. DP
(DIFFERENTIAL PRESSURE)
15KG/SQ.CM.
MINIMUM TEMPERATURE
(-)27 DEGREE C
MAXIMUM TEMPERATURE
55 DEGREE C
VISCOSITY AT
FLOW TEMPERATURE
PRESSURE DROP MAX/MIN
N CU.M./HR.
KG/SQ.CM.
LESS THAN 3
SECONDS
12KG/SQ.CM.
15KG/SQ.CM.
(-)27 DEGREE C
55 DEGREE C
0.5 CPS
0.5 CPS
MIN / NEGLIGIBLE
MIN / NEGLIGIBLE
CLOSE
OPERATOR TYPE
PISTON
SIZE
VTS
SPRING RETURN
TO CLOSE
80 dB
VTS
VTS
INDICATION
OPEN/CLOSE
CONTACT RATING
5A, 230V AC
MANUAL OVERRIDE
REQUIRED
REQUIRED
PORTS
3 WAY BRASS
VTS
1.
DPDT
2.
WITH SUPPLY
WITH SUPPLY
WITH SUPLY
1. Mfg. Standard
API 6D
2. Design
3. Stem
4. Construction
Single orifice
5. Port
6. Ends
50mm size & above
Bi-directional
7. Operation
ACTUATOR
8. Position of plug
To be clearly marked
10. Gland
Bolted
11.Approved make
TESTING :
1. Standard
2. Shell Test
3. Seat Test
4. Air Test
API 6D
80 kg/cm2.(G)
58 kg/ cm2.(G)
7 kg/ cm2.(G)
NOTE :
1 . THE TORQUE VALUE FOR OPERATING THE VALVE SHALL BE CLEARLY INDICATED
WITH SUPPORTING DOCUMENTS FROM THE MANUFACTURER.
2.
3.
DESCRIPTION
A.
1
2
3
4
5
6
7
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Stem
Construction
Port
Ends 50 mm size & above
Operation
9
10
11
B
1
Open/Close Condition
Min thickness for API 6D valves
Pressure relieving device for
body and bonnet cavity
Spring loading on body seat for
trunnion mounted ball
Gland
Back seat arrangement for
repacking under full working
pressure
MATERIALS
Body
Side/Tail piece
Ball
Stem
5
6
7
8
9
10
11
Stem(gland) packing
Back seal(stem ring)
Anti static ring
Gland nut
12
13
14
OUR REQUIREMENT
LPG
API 6 D
API 6F A
Blow out proof/Antistatic
2 piece/ 3 piece
Full bore / bi directional
Flanged
300#,
raised
face,
serrated
finish.
Flange details to ANSI B
16.5. Face to face to ANSI
B 16.10
Lever( worm gear for
150mm and above
To be clearly marked
As per ANSi B 16.34
Required
Required
Bolted
Required
VENDORS
ACCEPTANCE
/REMARKS
12
13
14
C
1
2
3
4
Lever
Lock Plate
Stop pin
TESTING
Standard
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
Carbon steel
Mild steel
Mild steel
API 598
79 kg/cm2(G)
57 kg/cm2(G)
7 kg/cm2(G)
DESCRIPTION
A.
1
2
3
4
5
6
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Stem
Construction
Port
8
9
10
B
1
Operation
Open/Close Condition
Pressure relieving device for
body and bonnet cavity
Gland
Back seat arrangement for
repacking under full working
pressure
MATERIALS
Body
Side/Tail piece
Ball
Stem
5
6
7
8
9
10
11
Stem(gland) packing
Back seal(stem ring)
Anti static ring
Gland nut
11
12
OUR REQUIREMENT
LPG
API 6 D
API 6F A
Blow out proof/Antistatic
3 piece
Full bore / bi directional,
floating ball
Socket welded to B16.11
with Sch 80 seamless pipe
extension piece 100mm
long on either side.
Lever
To be clearly marked
Required
Bolted
Required
VENDORS
ACCEPTANC
E/REMARKS
12
13
14
C
1
2
3
4
Lever
Lock Plate
Stop pin
TESTING
Standard
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
Carbon steel
Mild steel
Mild steel
API 598
210 kg/cm2(G)
152 kg/cm2(G)
7 kg/cm2(G)
DESCRIPTION
A.
1
2
3
4
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Stem
6
7
13
B
1
Bonnet
Discs
Above 50mm size
50 mm & below
Seat- body
Seat disc
Seat back
Operation
Back seat arrangement for
repacking under full working
pressure
Port
MATERIALS
Body
Bonnet
Disc(Wedge)
8
9
10
11
12
OUR REQUIREMENT
LPG
API 600/ 6 D
API 6 FA
Rising outside screw &
yoke (OS&Y)
Flanged
300#,
raised
face,
serrated
finish.
Flange details to ANSI B
16.5. Face to face to ANSI
B 16.10
Bolted
Split/Flexible wedge
Solid wedge
Renewable/integral
Renewable/integral
Renewable/integral
Hand wheel/non rising
Required
Full bore
Cast Carbon Steel, ASTM
A216 Gr WCB
ASTM A 105, Hard faced
with
Stellite
#6
or
equivalent
Cast Carbon Steel, ASTM
A216 Gr WCB
Cast Carbon Steel, ASTM
A216 Gr WCB + 13% Cr
Steel
Alloy Steel ASTM A193
VENDORS
ACCEPTANCE
/REMARKS
6
7
8
9
10
11
12
13
Back seat
Gasket
14
15
16
17
18
C
1
2
3
4
Eye bolt
Eye bolt nut
Groove pin
Yoke sleeve(stem nut)
Grease fitting
TESTING
Standard
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
B7/ A194 2H
13% Cr Steel
Graphite with braided end
rings
Steel
ASTM A182 Gr F.6.a
13% Cr Steel/SS 304
ASTM A216 Gr WCB +
13% Cr Steel
13% Cr Steel/SS 316
Spirally wound SS 304
with graphite filler
Cr Mo Steel
ASTM A194 Gr 2H
Steel
ASTM A 439 Type D2
Steel
API 598
79 kg/cm2(G)
57 kg/cm2(G)
7 kg/cm2(G)
DESCRIPTION
A.
1
2
3
4
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Stem
6
7
Bonnet
Discs
50 mm & below
Seat- body
Seat disc
Seat back
Operation
Back seat arrangement for
repacking under full working
pressure
8
9
10
11
12
OUR REQUIREMENT
LPG
API 600/ 6 D
API 6 FA
Rising outside screw &
yoke (OS&Y)
Socket welded to B16.11
with Sch 80 seamless
pipe
extension
piece
100mm long on either
side.
Bolted
Solid wedge
Renewable/integral
Renewable/integral
Renewable/integral
Hand wheel/non rising
Required
VENDORS
ACCEPTANCE
/REMARKS
13
B
1
Port
MATERIALS
Body
Bonnet
Disc(Wedge)
6
7
8
9
10
11
12
13
14
15
16
17
18
C
1
2
3
4
Back seat
Gasket
Eye bolt
Eye bolt nut
Groove pin
Yoke sleeve(stem nut)
Grease fitting
TESTING
Standard
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
Reduced bore
Cast Carbon Steel, ASTM
A216 Gr WCB
ASTM A 105, Hard faced
with
Stellite
#6
or
equivalent
Cast Carbon Steel, ASTM
A216 Gr WCB
Cast Carbon Steel, ASTM
A216 Gr WCB + 13% Cr
Steel
Alloy Steel ASTM A193
B7/ A194 2H
13% Cr Steel
Graphite with braided end
rings
Steel
ASTM A182 Gr F.6.a
13% Cr Steel/SS 304
ASTM A216 Gr WCB +
13% Cr Steel
13% Cr Steel/SS 316
Soft iron
13% Cr Steel
ASTM A194 Gr 2H
Steel
ASTM A 439 Type D2
Steel
API 598
210 kg/cm2(G)
152 kg/cm2(G)
7 kg/cm2(G)
DESCRIPTION
A.
1
2
3
4
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Stem
OUR REQUIREMENT
Water
API 600
API 6 FA
Rising outside screw &
yoke (OS&Y)
Flanged
150#,
raised
face,
serrated
finish.
Flange details to ANSI B
VENDORS
ACCEPTANCE
/REMARKS
13
B
1
Bonnet
Discs
Above 50mm size
50 mm & below
Seat- body
Seat disc
Seat back
Operation
Back seat arrangement for
repacking under full working
pressure
Port
MATERIALS
Body
Bonnet
Disc(Wedge)
Seat Ring
7a
Seat
7b
8
9
Back seat
Gland bush
Gland flange
10
Yoke nut
11
12
Gasket
Stem packing
13
14
15
16
17
Hand wheel
Hand wheel nut
8
9
10
11
12
Full bore
Cast Carbon Steel, ASTM
A216 Gr WCB
ASTM A 105, Hard faced
with
Stellite
#6
or
equivalent
Cast Carbon Steel, ASTM
A216 Gr WCB
Cast Carbon Steel, ASTM
A216 Gr WCB + 13% Cr
Steel
Alloy Steel ASTM A193
B7/ A194 2H
Carbon steel (vendor to
specify grade) with 13%
Cr. deposited
Stainless
steel,
AISI
4140/CA15
A 13% Cr Steel
Stainless steel, AISI 4140
Carbon Steel, AISI 4140
ASTM A105/ASTM A 216
Gr WCB
Ni resist CI/ASTM A 439
Type D2
ASTM A 308
Graphite with braided end
rings
Cr Mo Steel, ASTM A193
B7/ A194 2H
Cr Mo Steel, ASTM A193
B7/ A194 2H
Cr Mo Steel, ASTM A193
B7/ A194 2H
Steel
Steel
18
19
C
1
2
3
4
5
6
Grease nipple
Stem
TESTING
Standard
Shell Test
Seat test
Back seat
Air test
Pneumatic low pressure closure
test pressure
Steel
ASTM A 182 Gr F.6.A
API 598
32 kg/cm2(G)
22 kg/cm2(G)
21 kg/cm2(G)
7 kg/cm2(G)
API 598
DESCRIPTION
A.
1
2
3
4
5
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Type
Ends 50 mm size & above
6
7
8
B
1
Cover
Seat- body
Seat disc
MATERIALS
Body
3
4
Hinge
Disc
5
6
7
8
9
10
11
12
13
C
1
Disc seat
Disc nut
Disc nut pin
Hinge pin
Gasket
Cover
Stud & nut
Hinge pin cover
Hinge pin cover bolt
TESTING
Standard
OUR REQUIREMENT
LPG
API 600
API 6 FD
Swing
ASME B 16.5 Flanged
300#,
raised
face,
serrated finish. Flange
details to ANSI B 16.5.
Face to face to ANSI B
16.10
Bolted
Renewable/integral
Renewable/integral
Cast Carbon Steel, ASTM
A216 Gr WCB
ASTM A 105, Hard faced
with
Stellite
#6
or
equivalent
ASTM A216 Gr WCB
Cast Carbon Steel, ASTM
A216 Gr WCB + 13% Cr
Steel
Integral
SS 304/316
13% Cr Steel
13% Cr Steel
ASTM A 308
ASTM A216 Gr WCB
ASTM A193 B7/ A194 2H
ASTM A105
ASTM A193 B7
API 598
VENDORS
ACCEPTANCE
/REMARKS
2
3
4
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
79 kg/cm2(G)
57 kg/cm2(G)
25% of high pressure
closure test
DESCRIPTION
A.
1
2
3
4
5
CONSTRUCTION
Service
Design Standards
Fire Safe Certification
Type
Ends 50 mm size & above
6
7
8
B
1
Cover
Seat- body
Seat disc
MATERIALS
Body
3
4
Hinge
Disc
5
6
7
8
9
10
11
12
13
C
1
2
3
4
Disc seat
Disc nut
Disc nut pin
Hinge pin
Gasket
Cover
Stud & nut
Hinge pin cover
Hinge pin cover bolt
TESTING
Standard
Shell Test
Seat test
Pneumatic low pressure closure
test pressure
OUR REQUIREMENT
LPG
API 600
API 6 FD
Swing
ASME B 16.5 Flanged
300#,
raised
face,
serrated finish. Flange
details to ANSI B 16.5.
Face to face to ANSI B
16.10
Bolted
Renewable/integral
Renewable/integral
Cast Carbon Steel, ASTM
A216 Gr WCB
ASTM A 105, Hard faced
with
Stellite
#6
or
equivalent
ASTM A216 Gr WCB
Cast Carbon Steel, ASTM
A216 Gr WCB + 13% Cr
Steel
Integral
SS 304/316
13% Cr Steel
13% Cr Steel
ASTM A 308
ASTM A216 Gr WCB
ASTM A193 B7/ A194 2H
ASTM A105
ASTM A193 B7
API 598
32 kg/cm2(G)
22 kg/cm2(G)
25% of high pressure
closure test
VENDORS
ACCEPTANCE
/REMARKS
MATERIAL
DIMENSIONS
: ANSI B 16.5
ENDS
SCREEN
PERFORATED SHEET
: 16 GAUGE
TESTING
BODY
SA216
GR
BOLTS & NUTS SA193B7/A194 2H
WCB
1
2
3
1
2
3
8
1
2
3
4
5
6
7
8
9
DESCRIPTION
CONSTRUCTION
Quantity Nos
Service
Line size
Area Classification
STANDARDS
Design standards
OUR REQUIREMENT
1
LPG
2 (50NB)
Zone I Gr II A/ II B
Swing
As per BS 5351, full bore,
LL port, blow proof
system
API 607/6F/BS 6755 Pt2
API 598/6D/BS 6755 Pt1
Renewable/integral
Ball full bore
ANSI 300# RF
ASTM A216 Gr WCB
Teflon / Grafoil
Standard
On / Off
Soft seating /316 SSl
316 SS
Stainless Steel AISI 316 /
ASTM A 351 Gr. CF8M
(solid)
VENDORS
ACCEPTANCE
/REMARKS
10
11
12
13
C
1
2
3
4
Leakage Class
Stud & nut
Hinge pin cover
Allowable Sound level
TESTING
Standard
Body hydro Test
Seat hydro test
Seat air
V
ASTM A193 B7/ A194 2H
ASTM A105
85 DB
As per API 6 D /BS 6755
79 kg/cm2(G)
57 kg/cm2(G)
7 kg/cm2(G)
Item
: Seamless Pipes
2.
Material
3.
4.
Ends
5.
Length
6.
Size
7.
The tube shall confirm to the following standards in their sizes and weights:
S.No. NB
(mm)
1
200
2.
150
3.
100
4.
80
5.
50
6.
40
7.
32
8.
25
9.
20
10.
15
8.
SCHEDULE
40
40
40
40
40
80
80
80
80
80
OUTER DIA
(mm)
219.1
168.3
114.3
88.9
60.3
48.3
42.2
33.4
26.7
21.3
WALL THICKNESS
WEIGHT
(mm)
(kg/m)
8.18
28.55
7.11
18.97
6.02
16.07
5.49
11.29
3.91
5.44
5.08
5.41
4.82
4.47
4.55
3.24
3.91
2.20
3.73
1.62
Scope of third party inspection shall be review of Manufacturers test certificate for
the following:
1.
2.
3.
4.
5.
Visual
Dimensional Check
Tensile Requirement
Chemical Analysis
Bend / Flattening Tests
: 100%
: 100%
: One sample for each size of pipe and each heat
: One sample for each size of pipe and each heat
: One sample for each size of pipe and each heat
6. Hydrotesting
NOTE:
All the pipes shall be stamped by Third party inspection agency. The TPI stamping
shall be clearly visible on all pipes and the stamping mark to be mentioned in TPI
reports.
9. Third Party Inspection Agencies:
Our approved Third Party Inspection Agencies are :(i) EIL (ii) RITES (iii) Bureau
Veritas (iv) LLOYDS (v) IRS (vi) PDIL
Item
2.
Code
3.
Dimensional
Standard
4.
Ends
5.
Length
6.
Size &
Requirement
----------------------------------------------------------------------------------------Nominal size
IS Code
Thickness/
(NB in mm )
Class
----------------------------------------------------------------------------------------600 mm
IS 3589
12 mm
500 mm
IS 3589
10 mm
400 mm
IS 3589
8 mm
350 mm
IS 3589
8 mm
300 mm
IS 3589
7 mm
250 mm
IS 3589
7 mm
200 mm
IS 3589
6.35 mm
150 mm
IS 1239 (part I)
Heavy
100 mm
IS 1239 (part I)
Heavy
80 mm
IS 1239 (part I)
Heavy
65 mm
IS 1239 (part I)
Heavy
50 mm
IS 1239 (part I)
Heavy
40 mm
IS 1239 (part I)
Heavy
32 mm
IS 1239 (part I)
Heavy
25 mm
IS 1239 (part I)
Heavy
20 mm
IS 1239 (part I)
Heavy
15 mm
IS 1239 (part I)
Heavy
7.
Scope of third party inspection shall be Manufacturers test certificate for the
following:
1
2
3
4
5
6
Visual
: 100%
Dimensional (incl. wall thickness) Check
Tensile Requirement
: One sample
Chemical Analysis
: One sample
Bend / Flattening Tests
: One sample
Hydrotesting
: One sample
for
for
for
for
each
each
each
each
: 100%
size of pipe and each
size of pipe and each
size of pipe and each
size of pipe and each
heat
heat
heat
heat
NOTE:
All the pipes shall be stamped by Third party inspection agency. The TPI stamping
shall be clearly visible on all pipes and the stamping mark to be mentioned in TPI
reports.
8.
All LPG piping work shall be above ground and shall be of seamless Grade A 106
Gr.B Sch 80 upto 50 mm dia NB. The vent pipe shall be of schedule 40
2.
All piping flange joints shall be provided with 40 mm wide and 5 mm thick copper
jumpers. The pipe line shall be given the color code and the flow direction to
indicate the LPG liquid and vapour and the flow direction.
3.
All fittings and pipe work above 40mm dia NB shall be flanged, minimum 300#
rating as per ANSI 16.5 and with steel spiral wound gaskets except those required
as insulating joints.
4.
All fittings on LPG lines shall be forged fittings. Mitered fittings shall not be
allowed in LPG lines.
5.
6.
All pipe work leaving the tank is to be fitted with insulating flange kits.
7.
If a small size tapping is to be taken from a large dia pipe e.g. for taking tapping
for pressure gauges, for vent line for SRVs, PRV etc., the same shall be done using
a half coupling of specification mentioned below.
8.
9.
All studs and nuts shall be supplied zinc plated and material specifications shall
be as per ASTM A 193 Gr B7 for studs & ASTM A 194 Gr 2H for nuts.
10.
All pipe work shall comply with SMPV rules of CCOE, Nagpur, India. All piping shall
be rated for propane as per ASME B 31.3 with minimum design pressure of 32
kg/sqcm with a factor of safety of four. The materials of pipes shall be low carbon
or alloy steel conforming to American Standard ASTM-SA-333, grade 6 or API-5L.
The pipeline shall be tested at one and half times of the design pressure, if hydro
tested or ten percent in excess of design pressure if pneumatically tested.
11.
All ball/gate valves shall be suitable for LPG operations constructed as per
manufacturing standard API 6D and shall be fire safe as per API 607/BS
6755(PartII). CONTRACTOR TO SUBMIT TEST CERTIFICATE OF TPIA
CERTIFYING THE VALVES ARE MANUFACTURED AS PER API 6D AND ARE FIRE
SAFE.
SCOPE :
1.1
All the items of work covered under this tender shall be carried out as per the
specifications, drawings and details to be furnished to the Contractor. However,
the Engineer-in- charge/Site Engineer reserves the right at any time to give
additional/alternate specifications and instructions for erection of any particular
work and the Contractor shall execute such works in accordance with such
additional/alternate specifications and instruction of Site Engineer.
1.2
All acts, deeds, matters and things required to fulfill the Contractor's obligations
and to full fill municipal and or other statutory requirements for due execution of
the work shall be deemed to be included in the scope of work.
The scope of work under this technical specification covers:
Supply of all pipes(seamless for LPG & ERW for other), fittings, elbows,
tees, WNRF flanges 300# (for LPG applications), slip on flanges 150#,
blind flanges, full & half couplings, end caps etc.,
Transportation of contractor/owner supplied materials/equipment to all
places as required for the execution of this job.
Lifting of the equipment in the proper sequence so that safe and orderly
progress of the work is ensured.
Fabrication, erection and welding of the above ground and under ground
piping as per the following codes and standards
ANSI B 31.3
API 1104
2.0
TRANSPORTATION :
2.1
The work of transportation of Owner's supplied materials/ equipment include the
following :a)
All works and operations necessary to lift and to remove the materials/equipment
from Owner's designated stock- piles/store-yards/ godown, loading, handling,
transporting safely to the construction site and unloading by suitable means as
approved by the Engineer-in-charge/Site Engineer.
b)
Supply,
procurement, mobilisation and deployment of all labour, materials,
equipment and machinery necessary for lifting, removing, transporting and
unloading the Owner's supplied materials/equipment to the work sites.
c)
d)
It shall be the duty of the contractor to handle the equipment, valves, pipes and
fittings, coated lining material etc., in such a manner that no damage is done to
them. The contractor should also ensure that no damage while handling is done on
other materials.
e)
All other acts, deeds, matters and things whatsoever ancilliary, auxillary or
incidental to the above including but not limited to the grading and creation of
temporary approaches/accesses and ramps etc., as may be required.
f)
Transportation
of excess material from site to warehouse
loading/unloading and stacking as directed by owners/consultants.
3.0
including
LIFTING OF EQUIPMENT:
3.1
The Contractor shall be responsible for organising the lifting of the equipment in the
proper sequence, so that safe and orderly progress of the work is ensured. Rigging
procedures for all major lifts (upto 5.0 MT) and maximum crane capacity shall be
submitted by the Contractor to the Site Engineer. However, approval to rigging
procedure proposed by the contractor shall not relieve the Contractor from his
responsibility.
3.2
The slings used for lifting various loads shall be tested by a test load before carrying
out actual installation. The weight of the test load shall be 50% higher than the
weight of the equipment
to be lifted.
4.0
4.1
This specification covers the requirements for fabrication, erection, installation and
testing of above ground/underground piping system.
4.2
4.3
5.0
API 1104
ASME SECTION IX
IS : 823
6.0 FABRICATION :
The piping drawings specify the shape and dimensions of pipe
components sufficient for fabrication.
and piping
The dimensions indicated on the drawings are true and contain no allowance for
weld gaps.
Gaskets less than 1.5 mm thick (1/16" M) are ignored in dimensional computations.
All pipe branches shall be at 90 degree, unless otherwise indicated on the drawings.
Pipe cuttings shall be accurate, smooth and true to template, Slag & cutting dross
shall be removed before fitting.
Installation & protection during fabrication of the components
accordance with the manufacturer's installation instructions.
shall be in
TOLERANCES :
7.1
7.2
For pipes subjected to internal pressure, the difference between maximum and
minimum outside diameter at any section across the axis of bent portions shall not
exceed 5% of the nominal outside diameter. Wall thickness of the pipes after
bending shall not be less than 87.5% of the nominal wall thickness.
7.3
All linear dimensions involved in the relative position of branches, bosses, flanged
ends, instrument tapping and change in the direction to each other, shall be
maintained within + 3 mm ( + 1/8").
7.4
All angular dimensions of bends and branches shall be maintained within + 1/4
degree.
7.5
7.6
Alignment of flanges and branch welding ends measured across any diameter
shall not deviate from the indicated position more than 2.5 mm per meter ( 1/32"
per foot) of diameter.
7.7
8.0
8.1
Prior to aligning pipe for welding, the ends of the pipe shall be machine bevelled.
Bevel dimensions shall be as per applicable codes.
8.2
The bevelled ends of each joint of the pipe shall be thoroughly cleaned of paint,
rust, mill scale, dirt or other foreign materials to avoid defects in the completed
welds by methods approved by the site Engineer.
8.3
Any foreign matter or obstruction remaining inside the pipe shall be removed by
appropriate means.
8.4
Coupling and half coupling shall be accurately shaped and set on to suit the
contour of the run pipe.
8.5
8.6
Small tack welds i.e. between 12.5 mm (1/2") and 18 mm (3/4") in length
penetrating to the bottom of the groove may be used in fitting up.
8.7
Unless otherwise specified all pipe to pipe joints shall be butt welds.
8.8
Pipes with a wall thickness of 6 mm (1/4") and greater shall not have internal
misalignment of pipe wall exceeding 1.5 mm (1/16").
8.9
have internal
8.10
9.0
9.1.
9.2
Welding Process :-
9.2.1
Welding under this specification shall be done with following welding process
subject to the approval of Engineer-in-charge / representatives.
a)
Manual Metal Arc Process.
b)
Oxy - acetylene Welding Process.
9.2.2
Automatic or semiautomatic welding shall be made only with the specific approval
of the Engineer-in-charge, of the entire procedure and material.
9.2.3
9.3
Roots Pass : -
9.3.1
Root Pass shall be made with respective electrodes mentioned in the electrodes
specifications. The size of the electrode shall not be greater than 3.25 mm (10
SWG). Welding may be done with direct current with due regards to polarity and
current values recommended by the electrode manufacturers. Upward techniques
shall be adopted for welding pipes horizontally fixed in position. For thickness
less than 3 mm and pipe size 50 mm NB and below Oxy-acetylene welding is
recommended.
9.3.2
The soundness of weld depends to a large extent on complete fusion of the root
edges. Hence the root pass of butt joints shall be such as to achieve full
penetration. The depth of incomplete penetration shall not exceed 0.8 mm or 0.2
times wall thickness. The total length of such imperfections shall not exceed 38
mm in any 150 mm of weld length.
9.3.3
Welding shall not be interrupted during the root-pass, other than change of
electrode or change of welder's position.
9.3.4
9.3.5
9.3.6
Fillet welds shall be made by shielded metal arc process regardless of the
thickness and class of material. Electrode size shall not exceed 3.25 mm.
9.4
Joints Finishing : -
9.4.1
When the welding is completed, butt joints shall have a capping (cover pass) so as
to have gradual notch-free finish and good fusion at the joint edges.
9.4.2
The welds shall be free from undercuts and any other defects and shall have
regular appearance.
9.4.3
Welder's number shall be stamped clearly on each and every joint, adjustment to
the weld in order to identify the welder if defects are found after tests.
9.5
9.5.1
Owner's representative/agency appointed by the Owner will have free access to all
working places for inspection of procedures, quality etc., during working periods.
Contractor shall provide all assistance to carryout such inspections.
9.5.2
9.5.3
Visual examination shall be 100% on all the joints and shall reveal surface
defects such as misalignment, excessive reinforcement, concavity of the welds,
shrinkage, cracks, inadequate penetration, undercuts and surface porosity.
9.5.4
Radiographic examination shall be carried out on joints selected by Engineer-incharge. This will be 10 % on LPG Lines on a random basis. However, depending
the number of welders, and joints welded by each welder exceeds 100 Joints,
10% random will remain unchanged. But a minimum number of 5 joints in full
shall be radiographed from each
welder's joints if total number of joints
done by any welder are found below 100 joints of any size.
9.6
Radiographic Inspection :
The extent of radiography inspection coverage is as follows :
9.6.1
9.6.2
The welding engineer of the agency carrying out radiographic examination shall
submit the radiographs together with his findings, report and recommendation as
to the acceptability or otherwise of welds radiographed to the site engineer. The
site engineer's or his representative's decision as to the acceptability or otherwise
of the welds irrespective of the opinion or advice tendered by the welding engineer
shall be final and binding upon the contractor.
9.6.3
9.6.4
9.6.5
9.7
9.7.1
9.7.2
9.7.3
For carrying out the welding tests the contractor shall furnish the welding
equipment and electrodes. Test specimens, 2 1/2 cm in width, shall be cut from
the nipple at right angle to the weld. The test specimens shall be subjected to
tensile, root bend, face bend and neck break tests. These tests shall be arranged
by the Contractor at his own cost but shall be witnessed by Engineer-in-charge or
his representative.
9.7.4
The manner of performing the test and the results required shall be in accordance
with the code API-1104.
9.7.5
In the event that satisfactory results are not obtained the welder shall not be
employed on the job.
9.7.6
Welding Procedure qualification tests shall be carried out in accordance with job
requirements and the relevant requirements laid down in the above said Codes.
The Contractor shall submit the welding procedure to the Engineer-in-charge who
will check and approve the welding procedure after conducting the necessary
tests, prior to start of production welding. Standard tests shall be performed in all
cases. In addition to these standard tests, tests like macro examination, hardness
test, dye penetration examination, charpy V notch and U notch impact tests, etc.
shall be carried out on specimens depending on the type of base material,
operating conditions and requirement laid down in specification. It shall be the
responsibility of the Contractor to carry out all such tests.
9.8
STENCILLING OF WELDS :-
9.8.1
All welds shall be marked by the welders according to number assigned to them
by the
Contractor who will furnish to the Engineer-in-charge a record of all
number assigned. Should any welder leave during the course of the job, his stamp
shall be avoided and shall not be duplicated on the job.
(100 %).
9.8.2
9.9
WELDING PROCDEDURE : -
9.9.1
The pipe shall be aligned so that the longitudinal mill weld in the pipe is on the top
90 Degree of the pipeline (except on vertical bends) and in such a way that the
longitudinal mill welds are staggered not less than 45 degree.
9.9.2
Welding surfaces shall be thoroughly cleaned so as to be dry and free from paint,
oil, rust, scale and other materials detrimental to weld quality. Each bead shall be
cleaned of scale, oxides, dirt, slag and other impurities before any succeeding weld
passes are made.
9.10
D E F E C T S :-
9.10.1
Defects revealed by visual inspection, D.P. Test & Radiographic inspection of welds
shall be repaired/rectified by the Contractor at his cost to the satisfaction of the
Site Engineer. The repaired portion shall be re-examined by radiography. The
repairs carried out shall meet the approval of the Site Engineer.
9.11
WELDING CONSUMABLES :
9.11.1 Base Material : In general, the piping materials used are of Carbon Steel conforming to the
following specifications:
Pipes :
IS-1239/IS-3589 - ERW Heavy
A 106, Gr. B
(Utility Lines)
( LPG Lines)
Fittings:
A-234 Grade WPB B.W. -
MITRE Fittings:
To be fabricated from pipes supplied by contractor for sizes as per site requirement.
No mitre bends are allowed on LPG lines.
Flanges :
------SORF - A-105 150#/300# as per ANSI B16.5.
Filler Material :
---------------The contractor shall use welding rods, electrodes, as mentioned below :
{A 106 Gr. B )
E 6010
E7018
{IS-3589/
{IS-1239
E6010
E6013
Flanges {A 105
{IS:2062
E6010
E6010
E7018
E6013
Contractor to consider reputed makes like Advani Orlikon, Esab D & H. or Honavar for
electrode.
Welding Rods and Electrodes :
a. The electrodes shall be stored properly by the contractor to prevent moisture
absorption and shall be handled in such a manner as to avoid damage to the coating.
Manufacturer's
instruction in this connection shall be strictly followed.
b. All low Hydrogen type electrodes shall be completely dry when used. These shall be
pre dried in suitable ovens at controlled temperature of 200 - 250 Degree Celcius for
not less than four hours and then used on the job.
c. Electrodes, wire and flux, when used shall be free of rust, oil, grease, earth or any
other matter, which could be harmful for the quality of welding.
d. Electrodes of following makes shall be used :
1) Advani Oerlikon
2) D & H
3) ESAB
4) Honavar
9.11.2
The welding consumables used shall meet requirements of the relevant codes
and shall produce a deposit which is compatible in chemical analysis and similar
in mechanical properties to the parent material.
9.11.3
9.11.4
Before proceeding with welding, Contractor shall submit for approval to site
Engineer, Type, brand and size for each batch of consumables for use in each
class of piping.
9.11.5
9.12
9.12.1
Pipe work that has been done shall be checked with the relevant drawings and
other related documents to verify that it, as fabricated, complies with dimensions
and specifications.
9.12.2
Fabrication shall have dimensions falling within the tolerances defined earlier.
9.12.3
All welds shall be visually examined and shall also be subjected to radiographic
inspection as provided above.
9.12.4
Contractor shall provide tools/instruments like spirit levels, dumpy levels, scale,
tapes, gauges, calipers etc. for taking levels & measurements whenever required
by Engineer-in-charge.
9.13
Protection : -
9.13.1
When necessary the external surfaces of all fabricated pipe work shall be painted
with rust preventor or base primer to provide a protective coating against rust
during transit or storage.
9.13.2
Flanges and pipe ends, fitting, other components are to be protected by blank
flanges and plastic caps against mechanical damage and ingress of dust, dirt
and water, wherever necessary.
9.13.3
10.0
ERECTION :
10.1
The gaskets used during testing provided by the Contractor and these shall be
removed after the hydrostatic testing and new gaskets for permanent retention
shall be fixed only after flushing of the lines. New gaskets shall be provided by
HPCL.
10.2
All shop fabricated piping shall be routed and located in accordance with the
approved piping drawings. Utmost care shall be taken so that during erection no
damage will be done to the adjacent, valves etc.
10.3
Stud bolts and nuts for the LPG line flange joints shall be as per following
standards :
STUDS : A 193, Grade B7
NUTS
10.4
10.5
The assembly of various piping components shall be done so that the completed
erected piping conforms to the requirement of this specification good engineering
practice as well as meets the requirements of the engineering drawings.
10.6
While bolting gasketed flanged joints, the gaskets shall be properly located to
remain on the gasket sealing and tightened by hand to ensure that the gasket is
centered. Tightening by tools must be in diagonally and clockwise in increments
of 1/4, 1/2 of total load.
10.7
All bolts shall extend completely through their nuts by a least 2 threads to a
maximum of 3 mm projection.
10.8
10.9
Any mismatch found from shop welded piping, such as flange joints falling on pipe
supports (rack) or flanged joint of an adjacent piping interferes, drain point falling on
supports etc. shall be promptly rectified & installed by the Contractor.
10.10
10.10.1 For line size 50 NB and above the type and location of pipe supports are
indicated on the drawing. For site run piping 40 mm NB and below the type and locations
of the supports will be decided by the Contractor in consultation with the Engineer-incharge/representatives.
10.10.2 Where additional or temporary supports are required to be provided for erection
or testing, these shall be provided by the Contractor without any extra cost to Owner.
8.10.3 Field supports, `U' clamps and special supports are to be provided by the piping
Contractor. Welding of guides, shoes, pipes saddles to the pipes shall be within the scope
of piping
Contractor.
11.0
11.1
11.1.1 All piping, valves and fittings shall be cleaned thoroughly inside and outside using
detergent (quality approved by Owner) before erection.
11.1.2 All field fabricated piping shall be cleaned at the completion of fabrication. Care
shall be taken to see that all burrs, welding icicles, and weld spatter are removed by
reaming, chipping, filling or to her means. All foreign materials such as cement, mortar,
sand, heavy oil film and lose scale shall be removed from the interior of pipe by thoroughly
flushing with water.
11.1.3 All equipment, on-line instruments etc. shall be isolated by closing of valves or
slip blinds to protect such items before flushing and cleaning operation is started.
11.1.4 Strainer baskets and similar items shall be removed from the lines before
cleaning and replaced immediately after cleaning/flushing.
11.2
11.2.1 All possible precaution shall be taken to prevent dirt, grease, or other foreign
matters entering the valve. All foreign particles shall be removed by wiping with clean
linen cloth and
protected with suitable blinds till the valves erected.
12.0 HYDROSTATIC TEST AND PROCEEDURE :
12.1 Before carrying out the hydrostatic testing all line shall be thoroughly cleaned.
12.2 The pressure gauges to be used in testing shall be checked at instruments shops or
with any other outside agency designated by Owner/Contractor.
It shall be the
responsibility of the
Contractor to get the calibration of pressure gauges done.
12.3 Line shall be slowly filled with water. It shall be ensured that no air pockets will be
left over in the line.
12.4 All equipment such as pumps, vessels, relief valves, pressure gauges etc. shall be
disconnected from the piping or isolated by blinds or blanked off during the test.
12.5
All prefabricated and field welded lines shall be tested to the following pressures.
Lines should hold the pressure for at least half an hour prior to inspection. All butt joints
shall be inspected for leaks under pressure.
12.6 After erection of the pipe lines all the extended/modified lines if any upto nearest
isolation valve or any other point as modified by the Engineer-in-charge for the purpose of
this
specification shall be subjected to the same conditions as above.
12.7 When an existing line or portion thereby modified, cut or welded, this shall be
tested once again. The nature of the test and test pressure shall be same as above.
12.8 New lines connected with the existing lines will be tested by providing suitable
blanks before hooking-up. Such lines shall be drained, flushed and kept ready for hookup.
12.9 Valves installed on field welded line shall be considered as a part of piping and the
whole system shall be tested to the specified test pressure one side of the valve in shut-off
position shall be unbolted during the test in order to inspect the valve seating from the
open end.
12.10 Existing piping which has not been relocated or modified be isolated by blinds or
blanked off during the test.
12.11 Temporary line laying/connection with the existing system for testing purpose be
carried out at no extra cost to Owner.
12.12 When it is impracticable to isolate the piping to be tested, the condition for the
test shall be determined jointly by the Owner's and Contractor's representatives.
12.13 The Engineer-in-charge shall be notified well in advance by the Contractor of all
testing and such testing shall be witnessed by Engineer-in-charge/representatives.
12.14 Tests shall be considered complete only after Engineer-in- Charge gives approval
and records the line number.
12.15 All lines shall be drained fully after hydrostatic, testing and closed with suitable
blinds to prevent entry of dust or any foreign particles.
13.0 TEST RECORDS :13.1 Records shall be maintained for each piping system after testing. These records
shall contain the following information:
a)
b)
c)
d)
Date of Test.
Identification of Piping Tested (Line Number).
Test Fluid.
Approval by Owner/Consultant/Representatives.
14.0 FLANGE BONDING & GROUNDING :14.1 On all LPG Lines, provision for electrical bonding shall be provided on all flanged
joints. Copper flat strips of suitable width shall be used for bonding as per drawings.
Grounding
from such bonding shall be spaced at about every 75 m. (Grounding shall
be carried out by Electrical Contractor).
15.0 PAINTING
All the pipe lines (both ERW & seamless pipe lines) shall be sand blasted up to grade SA
2.5 as per Swedish standard SIS 055900 and the painting has to be carried out as
detailed below:
a) Surface preparation
: Grade SA 2.5
GENERAL
This specification describes a general outline for the installation of the equipment
involved. The field circumstances shall be taken into consideration and methods suitable
to the site conditions shall be adopted in consultation with and concurrence of the
erection supervisor, erection manuals and instructions. The successful accomplishment of
the project is greatly influenced by the team work, workmanship and skill of the workers
and supervisors. The Contractor shall employee only such workers and supervisors who
have considerable experience of similar work, temperamentally in good harmony and cooperation.
2.0
SCOPE OF WORK
The work under this contract shall include furnishing of all labour, tools, erection
equipment, consumable materials and other necessary materials not provided by owner.
He shall also provide other services required to take delivery of the equipment supplied by
the owner at the site, transport them to the site of erection, unpack, clean, assemble,
install, test and start up for commissioning all equipment as herein specified and shown
on the drawings. The work of erection/ installation, test and trial runs has to be carried
out in accordance with the manufacturer's instruction and/or drawings,
sketches/diagrams, and instructions given by the Engineer-in-charge.
The contractor shall also provide necessary labour and tools and tackles for unloading the
equipment from trucks, trailers, etc., whenever these are received at site, during the
tenure of contract.
3.0
3.1
All equipment issued to the contractor as free issue item from stores of the
Employer of Employer's agencies shall be checked by the contractor for the equipment
crates, boxes being intact, in the presence of Employer and shall be accepted by the
contractor for the storage and safe custody. Contractor for the storage and safe custody.
These equipment shall be loaded, transported, unloaded and stored in the manner
approved by Employer and the contractor shall be responsible for the safety of the
equipment during loading, unloading, transportation and storage.
3.2
Whenever the equipment is received in wooden crates/boxes the contractor shall
carefully dismantle these crates / boxes and store all timber and packing materials as
required by employer. All such packing materials shall remain the property of Employer.
3.3
It shall be the responsibility of the Contractor to study the requirements of
installation and instructions for commissioning of the same, by employing skilled
technicians experienced in the type of services required. The Contractor shall be fully
responsible for the safe custody of the equipment to commissioning and handing over of
the same to the Employer.
4.0
4.1
The Contractor shall take adequate care and precautions to prevent loss / damage
of material and equipment while in his custody. The responsibility of the contractor starts
from the time of withdrawal of equipment/material from Employer's custody till handing
over the same to Employer after complete erection and testing and surplus
material/equipment are accounted for and accepted by the Employer/consultant's
engineer. In case of loss or damage to any item or part thereof while in the custody of the
contractor, he shall be liable to pay cost of replacement of such item/damaged part
and/or cost of repairs to be carried out.
4.2
During the execution of the work the Contractor shall at his own cost keep
structures, materials and equipments adequately and safely braced by struts, guys and
any other approved means as required till installation is satisfactorily completed. The
Contractor shall design, provide and erect the struts, guys, shoring, bracing, planking
support in such way that they do not interfere with work of other agencies and shall not
damage or cause distortion to other works executed by him or other agencies.
4.3
Openings for level gauges, thermowells and other instruments shall be protected
during and after erection.
4.4
All accessories like pressure gauge, temperature indicators, safety
shall be tagged and kept separately till erection.
valves,
etc.
4.5
All flange connections and openings shall be kept blanked with wooden covers to
prevent entry of foreign matter, if not provided by the manufacturer's.
5.0
ERECTION OF EQUIPMENT
5.1
The Contractor shall make careful check of all the equipment before erection and
ensure that protective greases and wrapping applied on the machined surface and other
parts by the equipment supplier for protection during transportation and storage are
intact. Any defects noticed shall be reported and corrective action taken. Special care
shall be taken by the Contractor for bearings, rotating parts, etc. to prevent seizing.
Generally, the packages shall not be opened until required for installation. Orientation of
all the foundations, elevations, lengths, positions of anchor bolts and diameter of holes in
base plates, supporting saddles of equipment, etc., shall be checked by the Contractor
well in advance. Minor rectification work like chipping of foundation shall be carried out
by the Contractor after obtaining prior approval of the Employer/ Consultant's Engineer.
The Contractor will be provided with necessary equipment drawings of the related areas.
5.2
The Contractor shall also check the nozzle orientation on vessels/tanks and see
their compliance with the drawings and specifications supplied. Any discrepancy shall be
brought to the notice of Employer/Consultants Engineer and start work only after his
approval.
5.3
Rigging procedures of all major lifts above 5 MT and at maximum crane capacity,
shall be submitted by Contractor for approval of the Employer/Consultants' Engineer.
However, such approvals shall not relieve the Contractor from the responsibility of safe
rigging and lifting of the equipment, machinery etc.
5.4
Drilling and tapping of holes in base plates, fixing of couplings on shaft after
enlarging the pilot bores to correct size with keyways, etc. and dowelling including
provision of dowel pins or similar arrangement for retaining the alignment shall be carried
out by Contractor, as part of erection work.
5.5
All joints shall be assembled without undue stresses. Flanges must be parallel and
correctly aligned.
5.6
The Contractor shall study in details the complete work with the help of relevant
drawings, specifications and equipment suppliers special requirements specified in his
instructions manual. The Contractor shall prepare detailed procedures, outlined sequence
of operation, prepare time schedule for each operation and seek approval of
Employer/Consultants' Engineer.
5.7
Wherever necessary the Contractor shall remove the anticorrosive coating applied
on the machine/equipment by the supplier, carefully and completely with light oil
approved by the Employer/Consultants' Engineer.
5.8
After checking orientation and overall dimensions of the foundations, location and
sizes of anchor bolts, shape of foundation shall be checked as per foundation drawing with
reference to the equipment centre line.
5.9
On the chipped and prepared foundation surface, the contractor shall set up liners
for installation and centering of equipment. Liners shall be so arranged that the load of
equipment is uniformly and exactly distributed to the foundation. Liners shall be placed
as near as possible to both sides of anchor bolts. Where distance between anchor bolts is
too long additional liner shall be set up in between. The heights of each liner shall be
measured on the basis of standard level bench mark. The liners shall be fixed with
approximate grouting material.
The upper surface of the foundation shall be watered sufficiently, at least 24 hours prior to
setting of liners, to ensure good adhesion of grouting material.
5.10 The Contractor shall assemble, couple, fix, fit, install, level, align and grout the
equipment/materials on foundations, structures, platforms, floors, etc., as the case may
be. He shall bolt, weld, cut, drill, rivet and brace all components and fix them rigidly with
one another on the foundation supports etc.
5.11 All necessary shims scaffolding, temporary supports, staging, grouting, sand, etc.
required for erection of the equipment shall be provided by Contractor.
5.12
The Contractor shall assemble, position and fix all internals of the equipment.
6.0
6.1
Some of the equipment will be shipped by suppliers in knocked down condition.
All drive motors, etc. will be shipped separately. The contractor shall assemble all such
parts and sub-assemblies as per the manufacturer's/ supplier's/employer/consultant
engineer's instructions.
6.2
The contractor shall assemble, position and fix all internals of the equipment.
6.3
Method of lifting and handling of equipment and its sub-assemblies shall be
thoroughly discussed by the contractor with the engineer-in-charge. The equipment
wherever required shall be levelled for temporary setting using screw jacks at the lower
parts of common bed.
6.4
The contractor shall re-check the clearances of the part indicated by the engineerin-charge at the time of erection.
6.5
The centering or alignment of the equipment is done by the supplier in his factory.
However, there are chances of this alignment getting disturbed during transportation of
the equipment. The contractor shall, therefore recheck the alignment and take remedial
steps as per the instructions given in the installation manual of suppliers or as advised by
Engineer-in-charge, if any misalignment is observed. For motor driven equipment the
driving and driven shafts shall be fully aligned, deflection and face deviation of the shafts
shall individually be measured and it shall be confirmed that values are within the
tolerances. All readings of the inspection shall be properly recorded and submitted to
Engineer-in-charge. All alignment shall be done with Master level gauge, dial Gauge
etc. which will be arranged by the Contractor.
6.6
After completion of alignment, the equipment shall be erected in accordance with
procedure approved by Engineer-in-charge/Manufacturer. After perfect alignment of
driven shaft is achieved these shall be coupled and base plates shall be cleared for
grouting. Care shall be taken during grouting to see that the base plate level and
alignment are not disturbed.
7.0 THE EQUIPMENT ARE CLASSIFIED AS FOLLOWS :
(A)
(B)
7.1
7.1.1
Installation and centering of vessel, shall generally carried out in the order as
given below :(i)
( ii)
(iii)
the foundation. Centering of vessel for level and perpendicularity shall be carried out in
both directions intersecting at right angles on the same plans.
7.1.4 Prior to installation of the vessel, the contractor shall check the following with the
Engineer-in-charge suppliers's drawing/instruction manual :
(i)
( ii)
(iii)
7.2.1
(i)
Pump or Compressor.
( ii)
Motor or Engine.
(iii)
Base Plate.
parts, as -
The base plate may be either common or separate. They shall be erected on prepared
foundation by the Contractor and levelled with packing plates, shims and wages with the
help of precision levels and other instruments. The pump and the driver shall then be
coupled and aligned. After alignment the equipment shall be grouted by the Contractor.
Final alignment shall be done after all piping connections are made. Tolerances for
alignment shall be maintained as specified in the manufacturer's instruction manual, to
ensure that piping connections do not induce any stresses on the equipment. The
alignment shall be checked by the Contractor by disconnecting the piping or in the
working condition or in both conditions. Any connection necessary for proper alignment in
ambient and working conditions shall be carried out by the contractor as per the
instructions of the site-in-charge.
7.2.2 Levelling shall be carried out on four corners of the base plate ends for both the
directions of shaft and at right angle to the shaft.
7.2.3 The alignment of the unit shall be carried out on the basis of the finished surfaces,
which are as near as possible to the centre of the shaft.
7.2.4 Where adjustment between shaft and coupling is required for
the adjustments shall be carried out to the coupling and not to the shaft.
their
fitting,
7.2.5 The alignment of the unit shall be carried out until complete alignment of driving
and driven shaft is obtained. While aligning, the deflection and face deviation of the driving
and driven shaft shall individually be measured and should conform to the allowable limits
specified by supplier in his drawing/instruction manual.
7.2.6 After completion of alignment, it shall be conformed that the shaft can be rotate
smoothly and freely by hand.
7.2.7 After connection of piping, the alignment of the pump shall be rechecked. Any
misalignment induced by the piping connections shall be corrected by adjusting piping.
7.2.8 Running test of motor, diesel engine shall be performed with no load and it shall
be confirmed that vibrations, sound and temperature are not abnormal.
7.2.9 After running test of motor or engine, the driver and the
coupled with confirmation of rotating direction of unit and motor.
7.2.10 Trial running of the assembled unit shall be performed and it should be confirmed
that vibration, sound and temperature readings are within the acceptable limits specified
by the supplier.
7.3 TRIAL RUNS :
7.3.1 All pumps will be subjected to trial runs. The duration of trial runs shall be 72
hours continuous. Prior to carrying out trial runs, the equipment will be subjected to
necessary checkups by the Engineer-in-charge and trial runs shall be commenced only
after Engineer-in-charge's approval.
Contractor shall provide as part of the work necessary stilled personnel for conducting the
trial runs. The duration of the trial runs may be extended, if it is considered necessary in
the opinion of the Engineer-in-charge and the contractor shall provide personnel for such
extended period also without extra charge. Final inspection of bearings etc., shall be
carried out by the contractor, after the machinery is subjected to test, as part of testing.
During trial runs, details such as bearing temperatures, cooling water inlet and outlet
temperatures, temperatures in the lube oil system, outlet pressure, etc., shall be
recorded, wherever necessary, by the contractor. Test Reports shall be prepared in the
approved proforma, by the contractor, containing all the above details and submitted to
the Engineer-in-charge as part of the completion document.
8.0
8.1
The type of static and dynamic equipment to be installed, is given in the Schedule
of Rates. The Contractor shall fill in the applicable rates in the columns provided.
9.0 MISCELLANEOUS STEEL
All bolts, anchor bolts, nets, lock washers, supports and other miscellaneous items not
furnished by the equipment supplier or by the Employer or otherwise called for in this
specification shall be supplied by the Contractor. Before installing the equipment the
contractor shall verify location of bolts and if discrepancy exists he shall notify the
Employer.
10.0 GROUTING
10.1
Grouting of anchor bolts, holes, pockets and under base plates or under
equipment, have been broadly classified into two categories :
(A) Non-shrinking Grout
(B) Ordinary Grout.
A. Non-shrinking Grout
Non-shrinking grout consists of :One (1) Part of ordinary portland cement,
One (1) Part of clean dry well graded sand,
One (1) Part of ferro grout or similar additive approved by the Engineer-incharge,
minimum amount water just enough to make the mix place able.
Non-shrinking grout shall be generally used for grouting the following equipments
i)
ii)
iii)
B. Ordinary Grout
Ordinary grout consists of one (1) part of portland cement, two (2) parts of clean, dry
well graded sand, minimum amount of water just enough to make the mix placeable.
Ordinary grout shall be generally used for grouting the following equipments :
i) All structural framework.
ii) All other miscellaneous foundations.
The grouting material shall solidly fill the spaces to be grouted and permanently retain the
original volume so that the base plates are held firmly in the set position. The amount of
water used in the mixture shall be kept to a minimum just enough to make the mixture
placeable and for the grout to have a consistency too stiff for the grout to flow.
The top of the foundation shall be clean and free of all laithance, loose particles, oil,
grease, etc. shall be wetted thoroughly leaving no puddles prior to grouting. All trapped
pockets shall be repaired using ordinary grout. Under no account shall neat cement be
used for grouting.
11.0 PLACEMENT
a) All anchor bolt holes shall be completely filled with grout.
b) The finished surface shall be floated smooth and shall slope away from the base plate
(approximately 1:25).
c) After the initial set is over the grout shall be kept thoroughly wet for a minimum
period of 5 days.
d)
During grouting care shall be taken to ensure that the base plate level and the
alignment is not disturbed and that no honey-combing takes place in the grout.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
TECHNICAL SPECIFICATIONS
FOR
FIRE FIGHTING & SAFETY
ISI Certification Marked Stand Post type Water Monitor of 75 mm size consisting of 100
mm NB base flange, swivel joint, lock, water barrel, nozzle, handle etc. The monitor shall
be of M. S. Seamless construction, gunmetal/copper alloy swivel joints with locking
arrangement, duly treated with anti-corrosive treatment, nozzle of aluminium alloy,
permitting horizontal rotation of 360 deg. in either direction, 80 degree upwards and 45
degree downward traverse. The monitor shall be suitable for a discharge capacity of
minimum 2580 Ipm at a pressure of 7 Kg/cm2 having minimum horizontal throw of 60
mtrs and vertical throw of 30 mtrs. The water monitor shall be with ISI mark as per
IS:8442. All equipment to be inspected and approved by TPIA before dispatch and the
inspection report to be provided to HPCL for acceptance of the material.
2.
Hydrant post shall be stand post type with double outlet. The vertical post shall be 100
mm nominal dia. With two arms of 80 mm dia opposite to each other. The bottom inlet
flange of hydrant shall be 100 mm NB SORF flange conforming to ANSI B 16.5 150 Ibs
rating and 190 mm PCD. Both outlet flange shall be 80 mm dia. SORF flange conforming
to ANSI B 16.5 150 Ibs rating and 150 mm PCD. Independent gunmetal single headed
landing valves as per IS:5290 Type A bearing ISI Mark shall be provided on each outlet
point. The hydrant valves shall have instantaneous type female coupling outlet outlet
fitted with male blank cap. The coupling shall be as per IS903. Top end of hydrant shall
be blind and total height of the hydrant shall be 600 mm. The centre of the hydrant arms
shall be at a distance of 450 mm from the base flange. Both outlet flanges shall be at a
distance of 150 mm from the centre of vertical post in opposite directions. The hydrant
vertical post and hydrant arms shall be made of seamless black steel tube of heavy duty
conforming to IS:1239. Each assembly shall be hydrotested to a pressure of 15 kg/cm2
to check for flanged joint leaks. Each Hydrant post shall be painted with Fire Red colour
paint and shall be supplied along with two sets of gaskets. GI Nut Bolts, washers etc. All
equipment to be inspected and approved by TPIA before dispatch and the inspection
report to be provided to HPCL for acceptance of the material.
3.
63 mm x 15 mtrs. long cotton synthetic fibre seamless circular woven jacketed, rust proof,
rubberished fabric reinforced rubber lined fire hose, bearing IS:636/1988 Type-A mark
capable of withstanding 35.7 Kg. bursting pressure binded with gunmetal instantaneous
type male and female coupling hearing IS: 903 mark with copper wire. The hose and
coupling shall be ISI Marked. All equipment to be inspected and approved by TPIA before
dispatch and the inspection report to be provided to HPCL for acceptance of the material.
4.
Fibre Glass Fire Hose Box size: 750 mm x 600 mm x 250 mm (30 x 24 approx.),
moulded out of Fibre Reinforced Plastic (FRP) suitable for accommodating 02 Nos. of 15
metre Fire Fighting House with nozzle. The box shall be provided with double door and
shall have locking arrangements. Provision for break glass recess for key shall be given in
the box. The front doors shall be provided with transparent acrylic sheet fitted with rubber
beading for transparency. The box shall be painted with red colour glossy finish. The box
shall be capable to resist the weight of hose with couplings. Suitable wall mounting
bracket shall be provided in the cabinet. All equipment to be inspected and approved by
TPIA before dispatch and the inspection report to be provided to HPCL for acceptance of
the material.
5.
JET NOZZLES :
Jet nozzles with branch pipes made out of gunmetal suitable for 63 mm dia fire hose with
instantaneous coupling and 16 mm dia. Nozzle orifice capable of discharging 450 Ipm at
7 Kg/cm2 as per IS:903 ISI Mark. All equipment to be inspected and approved by TPIA
before dispatch and the inspection report to be provided to HPCL for acceptance of the
material.
6.
FOG NOZZLE :
Fog nozzle made out of gunmetal chromium plated suitable for 63 mm dia fire hose,
having arrangement for straight stream, high pressure fog and shut off as per IS:952 and
with coupling as per IS:903. All equipment to be inspected and approved by TPIA before
dispatch and the inspection report to be provided to HPCL for acceptance of the material.
7.
With ISI Mark-2171 (Latest) complete with initial charging of CO2 CARTRIDGE (200 gms)
with ISI Mark-4947 (Latest) and dry chemical powder with ISI Mark-4308 (Latest).
SPECIFICATIONS :
Size of filler opening (inner dia) not less than 75 mm.
Length of inner container not less than 35 cm.
Cap shall be of gunmetal with chromium plating.
Hose shall be of braided plastic high pressure with one meter length with nozzle of ABS
Plastic.
All other components, design and performance, anticorrosive treatment shall be as per
IS:1271 latest.
Certification that every extinguisher shall be of Radiographic quality welding and
fabrication and design of vessel shall be as per IS2825. 10% radiography of weld joints
& 50% "T" joints to be done. Design calculation of the extinguisher shall be submitted
along with the offer.
In addition to markings stipulated in IS:2171 (latest) the following permanent punching at
the bottom ring is required.
Manufacturer's name
Year of manufacturing
Manufacturers serial number
Purchase Order No. and date.
Inspector Stamp.
The date of hydraulic rest shall also be marked. Space shall be left for writing the
dates of subsequent hydraulic test
Made of 6 mm thick M.S. Sheet (B.Q. Plate & design of vessel as per IS:2825) with
radiography quality welding. The extinguisher shall be conforming to IS:10658-1983.
Extinguisher to be treated with anticorrosive treatment. Non ferrous parts shall be
gunmetal. Design calculation of the extinguisher shall be submitted along with the offer.
The hose shall be of minimum 05 mm meters length and the bursting pressure shall not
less than 50 Kg/Cm2.
Drain plug of not less than 25 mm diameter to be provided on the body.
The nozzle shall be of Trigger Controlled and capable of discharging powder as per ISI
Specification.
Automatically and manually operated Safety Relief Valve to be provided as per IS:10658
(Latest) specification.
Pressure gauge having minimum 50 mm dia. and range from 0 to 42 Kg/Cm2 to be
provided on the body.
The extinguisher to be mounted on robust trolley having two heavy duty bearing fitted
rubberised wheels and strong handles for easy mobility.
ISI Marked CO2 gas cylinder shall be of 2 Kg. Capacity and shall be approved by
Department of Explosives with protector and thermal insulation and to be fitted with ISI
marked wheel type Valve.
Dry Powder with ISI Mark IS:4308 (Latest). The powder shall be packed in plastic rigidex
material type bags with heavy duly LD lines duly hermetically sealed. The materials of
packing and sealing is to be made in such a way that if the pack is kept inside the water
bucket for 24 hours, not a single drop of water will penetrate inside the bag & the
characteristics of the powder shall remain unaffected against moisture.
Painting Two coats primer (red oxide) painting and then fire red painting by spray method.
As per IS-2825, Dye penetrated test of the fillet weld of all nozzles and attachment No
discontinuities in the welding.
As per IS:2825 Radiography (10% covering 50% of "T"
allowed.
Joints) -
No discontinuities
The extinguisher shall be hydro tested at 30 Kg/cm2 and shall not develop any leaks at
this pressure.
In addition to markings stipulated in IS:10658 (latest) the following permanent punching
at the bottom ring is required.
Manufacturer's name
Year of manufacturing
Manufacturers serial number
Purchase Order No. and date.
Inspector Stamp.
The date of hydraulic rest shall also be marked. Space shall be left for writing the
dates of subsequent hydraulic test
Dry Chemical Powder filling height shall be marked on the extinguisher.
All fire extinguishers shall be inspected and approved by TPIA before dispatch and the
inspection report to be provided to HPCL for acceptance of the material.
9
Dry Chemical Powder for fire fighting having chemical composition of sodium based,
shall be highly free flowing and siliconised to make powder water repellent and anti
caking. The powder shall be packed in rigidex imported materials bag with heavy duty LD
liners duly hermetically sealed. The material of packing and sealing is to be made in such
a way that if the packet is kept inside of the bucket full of water for 24 hours, the
characteristics of the powder shall remain unaffected against moisture.
The dry Chemical Powder shall be conforming to IS:4308-1982 with all the last
amendments and bearing ISI Mark.
10.
CO2 type 4.5 Kg. Capacity fire extinguisher assembled out of seamless steel cylinder
having Explosive (CCE) Approval and ISI Mark ( manufactured to IS:2878) complete with
ISI marked wheel type valve, one meter length high pressure wire braided discharge hose
with horn, wall mounting bracket and carrying handle. The cylinder shall be fully charged
with CO2 Gas. All other components, design and performance, anticorrosive treatment
shall be as per IS:2878 latest, In addition to markings stipulated in IS:2878 (latest) the
following permanent punching to be provided :
11.
Manufacturer's name
Year of manufacturing
Manufacturers serial number
Purchase Order No. and date.
Inspector Stamp.
LIST OF APPROVED MAKES :
Sensor Assembly
CONTROLLER
No of Channels / Inputs
Power supply
Mounting
Status Indication
Audio Alarm
Alarm setting
Alarm Levels
Operating Temperature
Calibration
Power Indication
Alarm knowledge
Supply of cables/FLP glands/FLP
enclosures for sensors/ Mounting
Accessories,
laying,
erection,
termination and commissioning
PENTAX,OLDHAM
or
approved
equivalent
LPG/Propane
FLP-1
Cast Aluminium LM-6
Surface
Catalytic Combustion type / 5 Nos
Flameproof to Gr II A and II B as per
IS:2148 and weather proof to IP 65
Sensor Transmitters along with FLP/ExP
housing to be approved by CMRS
Dhanbad and CCOE, Nagpur
SS 316
To be located in Control Room
5 / from sensor
230V AC, 50 Hz +/- 10%
Flush Panel Mounting
3 LEDs (Red, Yellow & Green)
Miniature buzzer built in
Slid switch
High : 1000 ppm
Medium : 500 ppm
Low : 100 ppm
Upto 50 deg C
Individual for each channel
Led
Push Button ( Common)
Included
TECHNICAL SPECIFICATIONS
FOR
CIVIL WORKS
CIVIL WORKS
GROUP-1: EARTHWORK
1.0
SCOPE :
This section covers general requirements of carrying out earthwork in excavation in
different materials, filling in areas as shown in drawings, backfilling in site grading,
around foundations, in plinths, etc., conveyance and disposal of surplus spoils or
stacking them properly as shown on the drawings & as directed by ENGINEER and all
operations covered within the intent & purpose of this specification.
2.0
3.0
GENERAL :
CONTRACTOR shall furnish all tools, plants, instruments, qualified supervisory personnel,
labour, materials, any temporary works, consumables, anything and everything necessary,
whether or not such items are specifically stated herein, for completion of the job in
accordance with specification and requirements.
CONTRACTOR shall carry out the survey of the site before commencing excavation and set
properly all lines and establish levels for various works such as earthwork in excavation for
site grading, foundations, plinth filling, roads, drains, cable trenches, pipelines, etc. Such
survey shall be carried out by studying thoroughly the drawings for the existing plant and
modus operandi for earthwork shall be discussed with ENGINEER. Ground levels shall be
taken and properly recorded by the CONTRACTOR and shall be checked and certified by
ENGINEER.
The excavation shall be carried out to correct lines and levels. This shall also include,
where required, proper shoring to maintain excavations and also the furnishing, erecting
and maintaining of substantial barricades around excavated areas and warning lamps to
ensure safety at night.
The rates quoted shall also include for dumping of excavated materials in required heaps,
bunds, riprap with regular slope as directed by ENGINEER, within the lead specified and
leveling the same so as to provide stability and natural drainage. Soil excavated shall be
stacked properly as directed by ENGINEER. As a rule, all softer materials shall be laid
along the centre of heaps, the harder and more weather resisting materials forming the
casing on the sides and the top.
4.0
CLEARING :
The area to be excavated, and / or filled shall be cleared of fences, plants, bushes,
vegetation, slush, etc. and other objectionable matter. The materials so removed shall be
disposed off as directed by ENGINEER. Where earth fill is intended, the area shall be
stripped of all loose / soft patches, top soil containing objectionable matter / materials
removed before fill commences.
5.0
5.1
5.2
DEWATERING :
All excavation shall be kept free of water. Grading in the vicinity of excavation shall be
controlled to prevent surface water running into excavated areas. CONTRACTOR shall
remove by pumping or other means approved by ENGINEER any water, inclusive of rain
water and subsoil water accumulated in excavation, and keep all excavations dewatered
until the foundation wok is completed and backfilled. Sumps made for dewatering must
be kept clear of the excavations / trenches required for further work. Method of pumping
shall be approved by ENGINEER but in any case, the pumping arrangement shall be such
that there shall be no movement of subsoil or blowing in thereof due to differential head of
water during pumping. Pumping arrangements shall be adequate to ensure no delays in
construction.
When there is a continuous inflow of water and quantum of water to be handled is
considered, in the opinion of ENGINEER, as large, well point system. Single stage or
multistage, shall be adopted. CONTRACTOR shall submit to ENGINEER his scheme of well
point system including the stages, the spacing, number of diameter of well points,
headers, etc. and the number, capacity and location of pumps for approval. The cost of
dewatering shall be included in the items for excavation.
FILL AND BACK FILLING :
GENERAL :
All fill material shall be subject to ENGINEERs approval. If any material is rejected by
ENGINEER, CONTRACTOR shall remove the same forthwith from the site within 24 hours
at no extra cost to the OWNER. Surplus fill material shall be deposited / disposed off as
directed by ENGINEER after the fill work is complete.
No earthfill shall commence until surface drains have been properly intercepted, or
otherwise properly dealt with, as directed by ENGINEER.
MATERIAL :
Only selected excavated materials shall be used as backfill. Fill material shall be free from
clods, silt, salts, sulphates, organic or other foreign material. All clods of earth shall be
removed.
If any selected fill material is required to be borrowed, CONTRACTOR shall make
arrangements for bringing such material from outside borrow pits. The material and
source shall be subject to prior approval of ENGINEER. The approved borrow pits areas
shall be cleared of all bushes, plants, rubbish, etc. Top soil containing salts / sulphate
and other foreign material shall be removed. The materials so removed shall be disposed
off, as directed by ENGINEER.
FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS OF STRUCTURES, WALLS,
ETC.
As soon as the work in foundation has been accepted and measured, the space around
the foundations, structures, pits, trenches, etc. shall be cleared of all debris and filled
with earth in layers not exceeding 15 cm., each layer being watered, rammed and
properly consolidated, before the succeeding layer is laid. Each layer shall be
consolidated to the satisfaction of ENGINEER. Earth shall be rammed with approved
mechanical compaction machines. Usually no manual compaction shall be allowed unless
ENGINEER is satisfied that in some cases manual compaction by tampers is unavoidable.
The final backfilled surface shall be trimmed and leveled to proper profile, as shown on
the drawings and as directed by ENGINEER.
SAND/MURUM FILLING IN OTHER PLACES :
At places backfilling shall be carried out with local sand/murum if directed by ENGINEER.
The sand /murum used shall be clean, medium grained and free from impurities. The
filled-in-sand shall be kept flooded with water for 24 hours to ensure maximum
consolidation. Any temporary work required to contain sand under flooded condition shall
FILLING IN TRENCHES :
Filling in trenches for pipes and drains shall be commenced as soon as the joints of pipes
and drains have been tested and approved by ENGINEER. The backfilling material shall be
properly consolidated by watering and ramming, taking due care that no damage is
caused to the pipes.
In case of trenches in cutting, the filling upto a level 30 cm above the top of the pipe shall
be carried out with approved fine materials, such as earth, sand, murum, etc. The filling
upto the level of the centreline of the pipe shall be carried out by hand compaction in
layers not exceeding 8 cm. Whereas, the filling above the centreline of the pipe shall be
carried out by hand compaction or by approved means in layers not exceeding 15 cm, the
filling from a level 30 cm. above the top of the pipe to the top of the trench shall be
carried out manually or other approved mechanical methods, as directed by ENGINEER.
Filling of the trenches shall be carried out simultaneously on both sides of the pipe to
avoid unequal pressure on the pipe.
7.0
7.1
1.0
1.0 SCOPE :
This specification covers the general requirements for concrete to be used on jobs using
on-site production facilities including requirements in regard to the quality, handling,
storage of ingredients, proportioning, batching, mixing & testing of concrete, and also
requirements in regard to the quality, storage, bending and placement of reinforceme
This also covers the transportation of concrete from the mixer to the place of final deposit
and the placing, curing, protecting, repairing and finishing of concrete.
2.0
I.S. : 432 - Specification for mild steel and medium tensile steel
(parts I & II) bars and hard drawn steel wire for
concrete reinforcement.
IS : 456 - Code of practice for plain and reinforced concrete.
IS : 516
concrete work irrespective of mix, whether reinforced or otherwise, and shall conform to
the applicable clauses of this specification.
4.0 MATERIALS FOR STANDARD CONCRETE :
The ingredients to be used in the manufacture of standard concrete shall consist solely of
a standard type Portland Cement, clean sand natural coarse aggregate, clean water, and
admixtures, if specially called for on drawings and/or in the specifications.
4.1 CEMENT :
Unless otherwise specified, cement shall be High Strength Ordinary Portland Cement
(Grade 43/53 ) of approved make in 50 kg bags. Changing of brands or type of cement
within the same structure will not be permitted. CONTRACTOR shall make his own
arrangements for the storage of adequate quantity of cement.
Approved makes are : Ultratech/JKLaxmi/Birla-Uttam/Birla Diamond & prism,
/Vasavdatta/ ACC/ Nagarjuna /JPRewa /Gujarat Ambuja /Bhima of Coramandal /Zuari
Cement bags shall be stored in a dry enclosed shed (storage under tarpaulin will not be
permitted), well away from the outer walls and insulated from the floor to avoid contact
with moisture from ground & walls, and so arranged as to provide ready access. Damaged
or reclaimed or partly set cement will not be stacked in any tier and shall be stacked
separately or removed from shed. The storage arrangement shall be approved by
ENGINEER. Consignment of cement shall be stored as received and shall be consumed in
the order of their receipts at site.
Cement held in storage for a period of ninety (90) days or longer shall be tested. Should at
any time ENGINEER has reasons to consider that any cement is defective, then
irrespective of its origin, date of manufacture and/or manufacturers test certificate, such
cement shall be tested immediately at a National Test Laboratory/Approved Laboratory
and until the results of such tests are found acceptable, it shall not be used in any work.
CONTRACTOR shall not be entitled to any claim of any nature on this account.
4.2 AGGREGATES :
4.2.1 GENERAL :
a) Aggregates in general designate both fine and coarse inert materials use in the
manufacture of concrete.
b) Fine Aggregates are aggregates most of which pass through 4.75 mm IS sieve.
c) Coarse Aggregates are aggregates most of which are retained on 4.75 mm IS sieve.
All fine and coarse aggregates proposed for use in the work shall be subject to
ENGINEERs approval and after specific materials have been accepted, the source of
supply of such materials, shall not be changed without prior approval of ENGINEER.
Aggregates shall, except as noted above, consist of natural sands, crushed stone and
gravel from a source known to produce satisfactory aggregate for concrete and shall be
chemically strong, hard, inert, durable against weathering, of limited porosity and free
from deleterious materials that may cause corrosion of the reinforcement or may impair
the strength and/or durability of concrete. The grading of aggregates shall be such as to
produce a dense concrete of specified strength & consistency that will work readily into
position without segregation and shall be based on test on concrete, as specified later in
this group.
4.2.2. FINE AGGREGATES :
4.2.2.1 GENERAL :
Fine aggregates, except as noted above, shall consist of natural or crushed sand
conforming to IS : 383. The sand shall be clean, sharp, hard, strong and durable and shall
be free from dust, vegetable substances, adherent coatings, clay, alkali, organic matter,
mica, salt, or other deleterious substances which can be injurious to the setting
qualities/strength/durability of concrete.
4.2.2.2 SCREENING AND WASHING :
Sand shall be prepared for use by such screening or washing or both, as necessary, to
remove all objectionable foreign matters while separating the sand grains to the required
size fraction.
4.2.2.3 FOREIGN MATERIAL LIMITATIONS :
The percentage of deleterious substances in sand shall conform to IS : 383.
4.2.2.4 GRADATION :
Unless otherwise directed or approved, the grading of sand shall be within the limits
indicated hereunder :
---------------------------------------------------------------------------------------------------I.S. Sieve
PERCENTAGE PASSING FOR
Designation
Grading
Grading
Grading
Grading
Zone-I Zone-II Zone-III
Zone-IV
---------------------------------------------------------------------------------------------------10.00 mm
100
100
100
100
4.75 mm
90 100
90 100
90 100
95 100
2.36 mm
60 95
75 100
85 100
95 100
1.18 mm
30 70
55 90
75 100
90 100
600 micron
15 34
35 59
60 79
80 100
5 20 8 30 12 40
15 50
300 micron
150 micron
0 10 0 10 0 10
0 - 15
----------------------------------------------------------------------------------------------------Where the grading falls outside the limits of any particular grading zone of sieves, other
than 600 micron I.S. sieve, by total amount not exceeding 5 %, it shall be regarded as
falling within that grading zone. This tolerance shall not be applied to percentage passing
the 600 micron I.S. Sieve or to percentage passing any other sieve size on the coarser
limit of Grading Zone I or conforming to Grading Zone IV shall be used. Sand used for
preparing concrete shall belong to Grading Zone-II.
Mix design will be carried out giving proportions of the ingredients, sources of
aggregates and cement, along with accompanying test results of trial mixes as
per IS : 10262 shall be submitted to the ENGINEER for his approval before it
is used for the works.
5.1.1 PROPORTIONING AND WORKS CONTROL :
5.1.1.1 GENERAL :
Proportioning of ingredients of concrete shall be made by any of the two
following two methods, as directed by ENGINEER.
a) With preliminary tests by designing the concrete mix. Such concrete shall
be called Design Mix Concrete.
b) Without preliminary tests, adopting Nominal Mix Concrete.
As far as possible, controlled concrete shall be used for all concrete works.
Ordinary concrete in grades permitted in accordance with IS : 456 may be
used if shown on drawings or approved by the ENGINEER. In all cases the
proportioning of ingredients and works control shall be in accordance with IS :
456 and shall be adopted for use after the ENGINEER is satisfied regarding its
adequacy and after obtaining his approval in writing.
5.1.1.2 MIX DESIGN CRITERIA :
Concrete mixes will be designed by the CONTRACTOR to achieve the strength,
durability and workability necessary for the job, by the most economical use
of the various ingredients. In general, the design will keep in view the following
considerations :
Consistent with the various other requirements of the mix, the quantity of
water shall be kept at the lowest possible level.
The nominal maximum size of coarse aggregate shall be as large as possible
within the limits specified.
The various fractions of coarse and fine aggregates should be mixed in such a
proportion as to produce the best possible combined internal grading giving
the densest and most workable mix.
The finished concrete should have adequate durability in all conditions to
withstand satisfactorily the weather and other destructive agencies the
structure is expected to be subjected to in actual service.
The requirement of adequate structural strength is catered for by the choice
of proper grade of concrete by the ENGINEER. The CONTRACTOR shall strictly
abide by the same in his design concrete mix.
Notwithstanding anything mentioned in various tables given in IS: 456 giving
specific values and degrees of workability for different condition of concrete
placing minimum cement content and maximum water-cement ratio for
concrete exposed to sulphate attack and for concrete to ensure durability
under different conditions of exposure, strength requirement for different
grades of concrete.
5.1.3
STRENGTH REQUIREMENT :In case of D In case of Design Mix Concrete, the water cement ratio of such value has to
give acceptable test results as per IS : 456, will be selected by trial and error. The values
of water-cement ratios for different concrete grades and mix designs shall be established
after conducting sufficiently large number of preliminary tests in the laboratory to the
satisfaction of the ENGINEER. Frequent checks on tests shall be carried out and the
water-cement revised if the tests produce unsatisfactory results. Notwithstanding
anything stated above, CONTRACTORs responsibility to produce satisfactory test results
and to bear all the consequences in case of default remain unaltered.
In case of ordinary concrete, the maximum water-cement ratio for different grades of
concrete specified in Table-3 of IS : 456 and no tests are necessary. The acceptance test
criteria for nominal mix concrete shall be as per IS : 456.
5.2
SURFACE PREPARATION
5.2.1
5.2.2
5.2.3
its initial and final set. This method shall be used wherever practicable and shall consist
of cutting the surface with picks and stiff brooms and by use of an approved combination
of air and water jet as directed by ENGINEER. Utmost care shall be exercised in
performing this work to removal of mortar and the weakening of the surface by loosening
of aggregates.
The final required result shall be that pitted surface from which all dirt, unsound
concrete, laitance and glazed mortar have been removed.
5.2.4
5.2.5
5.3
5.4.1
5.4.2
5.4.3
AVOIDING SEGRETATION :
Concrete shall, in all cases, be placed from as near as practicable position directly in its
final position, and shall not be re-handled or caused to flow in a manner which will cause
segregation, loss of materials, displacement of reinforcement, shuttering or embedded
inserts, or impair its strength.
For locations where direct placement is not possible, and in narrow forms, CONTRACTOR
shall provide suitable chute and Elephant Trunks to confine the movement of concrete.
5.4.4
5.4.5
5.4.6
BLEEDING :
Should bleeding of free water on top of concrete being placed into the forms occur, the
conditions causing this defect shall be corrected before further concreting is resumed.
5.5
COMPACTION :
5.5.1
GENERAL :
Concrete shall be compacted during placing, with approved vibrating equipment until the
concrete has been consolidated to the maximum practicable density, is free of pockets of
coarse aggregates and fits tightly against all form surfaces, reinforcement and embedded
fixtures. Particular care shall be taken to ensure that all concrete placed against the form
faces and into corners of forms or against hardened concrete at joints is free from voids
or cavities. The use of vibrators shall be consistent with the concrete mix and caution
exercised not to over vibrate the concrete to the point that segregation results and water
appears on the top surfaces.
5.5.2
USE OF VIBRATORS :
The exact manner of application and the most suitable machines for the purpose must be
carefully considered and operated by experienced men. Immersion vibrators shall be
inserted vertically at points not more than 450 mm apart and withdrawn when air
bubbles cease to come to the surface. Immersion vibrators shall be withdrawn very
slowly. In no case shall immersion vibrators be used to transport concrete inside the
forms.
Particular attention shall be paid to vibration at the top lift of wall.
5.5.3
PENETRATION OF VIBRATORS :
The immersion vibrator shall penetrate the layer being placed and also penetrate the
layer below while the under layer is still plastic, to ensure good bond and homogeneity
between the two layers and prevent the formation of joints.
5.5.4
5.6
5.7
5.7.1
GENERAL :
Concrete shall be placed without interruption until completion of the part of the work
between predetermined construction joints, as specified hereinafter. Time lapse between
the pouring of adjoining units shall be as specified on the drawings or as directed by
ENGINEER.
If stopping of concreting becomes unavoidable anywhere, a properly formed construction
joint shall be made where the work is stopped. Joints shall be either vertical or horizontal
unless otherwise shown on drawings. In case of an inclined or curved member, the joint
shall be at the right angles to the axis of the member. Vertical joints in walls shall be kept
to a minimum. Vertical joints shall be formed against a stop board; horizontal joints shall
be level and wherever possible, arranged so that the joint lines coincide with the
architectural features of the finished work. Battens shall be nailed to the form work to
ensure a horizontal line, and if directed, shall also be used to form a grooved joint. For
water storage bullet walls and similar work, joints shall be formed as per IS : 3370.
Concrete that is in the process of setting shall not be disturbed or shaken by traffic either
on the concrete itself or upon the shuttering. Horizontal and vertical construction joints
and shear keys shall be located and shall conform in detail to the requirements of plans,
unless otherwise directed by ENGINEER IN CHARGE.
5.7.2
DOWELS :
Dowels for concrete work, not likely to be taken up in the near future, shall be encased in
concrete as per drawings and as directed by the ENGINEER.
5.7.3
5.7.4
5.8
5.9
BONDING MORTAR :
Immediately before concrete placement begins, prepared surfaces except formwork,
which will come in contact with the concrete to be placed, shall be covered with the
bonding mortar.
5.10
CLEANING OF EQUIPMENT :
All equipment used for mixing, transporting and placing of concrete shall be maintained
in clean condition All pans, buckets, hoppers, chutes, pipelines & other equipment shall
be thoroughly cleaned after each period of placement.
5.11
5.11.
1
CURING :
5.11.
2
All concrete shall be cured by keeping it continuously damp for the period of time
required for complete hydration and hardening to take place. Preference shall be given to
the use of continuous sprays, or ponded water, continuously saturated coverings of
sacking, canvas, hessians or other absorbent materials, or approved effective curing
compounds applied with spraying equipment capable of producing a smooth, eventextured coat. Extra precautions shall be exercised in curing concrete during cold and hot
weathers as outlined hereinafter. The quality of curing water shall be the same used for
mixing concrete.
Fresh concrete shall be kept continuously wet for a minimum period of 14 days from the
date of placing of concrete, following a lapse of about 12 hours after laying concrete.
The curing of horizontal surfaces exposed to the drying winds shall, however, begin
immediately after the concrete has hardened. Water shall be applied to unformed
concrete surfaces within 1 hour after concrete has set. Water shall be applied to formed
surfaces immediately upon the removal of forms. Quantity of water applied shall be
controlled so as the prevent erosion of freshly placed concrete.
5.11.
3
CONTINUOUS SPRAYING :
5.11.
4
CURING EQUIPMENT :
5.12
Curing shall be assured by use of an ample water supply under pressure in pipes, with all
necessary appliance of hose, sprinkle and spraying devices. Continuous fine mist
spraying or sprinkling shall be used, unless otherwise specified or approved by
ENGINEER.
All equipment and materials required for curing shall be on hand and ready for use
before concrete is placed.
Fresh concrete shall be protected from the elements, from defacement & damage due to
construction operations by leaving forms in place for an ample period as specified later
in this specification. Newly placed concrete shall be protected by approved means such
as tarpaulins from rain, sun & winds. Steps, as approved by ENGINEER, shall also be
taken to protect green concrete from damage by debris, excessive loading, vibration,
abrasion or contact with other materials, etc. that may impair the strength and/or
durability of the concrete. Workmen shall be warned against and prevented from
disturbing green concrete during its setting period. If it is necessary that workman have
to enter the area of freshly placed concrete bridges be placed over the area, as directed
by ENGINEER.
5.13
5.13.
1
GENERAL :
5.14
Immediately after the shuttering is removed, the surface of concrete shall be very
carefully gone over all defective areas called to the attention of ENGINEER. Defective
areas shall be repaired or replaced by CONTRACTOR as directed by HPCL at no
additional cost to HPCL..
Facilities required for sampling materials and concrete in the field, shall be provided by
CONTRACTOR at no extra cost.
Test cubes for each grade of concrete and for quantity placed in each pour shall be
made as specified in IS : 456. Such samples shall be drawn on each day, for each grade
of concrete & during each concreting operations. Additional cubes shall be taken for 7
days test as required by ENGINEER. The laboratory test results shall be tabulated
maintained at site and furnished to ENGINEER. ENGINEER will accept the concrete
according to Acceptance Criteria specified in the IS : 456.
5.15
CONSISTENCY :
Slump test shall be carried out as often as demanded by ENGINEER invariably from the
same batch of concrete from which the test cubes are made. Slump test shall be done
immediately after sampling.
LIMITS OF CONSISTENCY
Degree of workability
5.16
Very low
Low
25
50
Medium
25
75
5.17
6.0
FORMWORK :
The formwork shall consist of shores, bracings, sides of beams and columns, bottom of
slabs, etc. including ties, anchors, hangers, inserts, etc. complete which shall be properly
designed and planned for the work. False work shall be so constructed that vertical
adjustments can be made to compensate for take up and settlements. Wedges shall be
used at the top or bottom of timber props, but not at both ends, to facilitate vertical
adjustment or dismantling of the formwork.
6.1
DESIGN OF FORMWORK :
The design and engineering of the formwork as well as its construction shall be the
responsibility of CONTRACTOR. If so instructed, the drawings and/or calculations for the
design of the formwork shall be submitted to ENGINEER for approval before proceeding
with work, at no extra cost to OWNER. ENGINEERs approval shall not, however, absolve
the CONTRACTOR of his full responsibility for the design and construction of the
formwork. The design shall take into account all the loads, vertical as well as lateral,
forms would be carrying, including live and vibration loadings.
6.2
FORMWORK REQUIREMENTS :
Forms shall conform to the shapes, lines, grades and dimensions, including camber of
the concrete as called for on the drawings. Ample studs, walers, braces, ties, straps,
shores, etc. shall be used to hold the forms in proper position without any distortion
whatsoever until concrete has set sufficiently to permit the removal of forms. Forms shall
be strong enough to permit the use of immersion vibrators. The formwork shall be close
boarded. Timber shall be well seasoned, free from sap, shakes, loose knots, work holes,
warps or other surface defects. Faces coming in contact with concrete shall be free from
adhering grout, plaster, paint projecting nails, splits or other defects. Joints shall be
sufficiently tight to prevent loss of water and cement slurry from concrete.
Plywood shall be used for Exposed Concrete surfaces; where called for Sawn and wrought
timber may be used for unexposed surfaces. Inside faces of forms for concrete surfaces
which are to be rubbed finished shall be planed to remove irregularities or unevenness in
the face. Formwork with linings will be permitted.
All new and used material for lumber shall be maintained in a good condition with
respect to shape, strength, rigidity, water tightness, smoothness and cleanliness of
surfaces. Form lumber unsatisfactory in any respect shall not be used and, if rejected by
ENGINEER, shall be removed from the site.
Formwork, during any stage of construction showing signs of distortion or distorted to
such a degree that the intended concrete work will not conform to the exact contours
shown on the drawings, shall be repositioned and strengthened. Poured concrete affected
by the faulty formwork, shall be removed in its entirety and the formwork corrected, as
directed by ENGINEER, prior to placing new concrete.
Forms for substructure concrete may be omitted when, in the opinion of ENGINEER, the
open excavation is firm enough to act as the form. Such excavation shall be slightly larger
than that required by the drawings to compensate for irregularities in excavation and to
ensure concrete cover and the design requirements.
Forms shall be so designed and constructed that their removal will not damage the
concrete. Face formwork shall provide true vertical and horizontal joints, conform to the
architectural features of the structure as to location of joints and be as directed by
ENGINEER.
When exposed smooth or rubbed concrete finishes are required, the forms shall be
constructed with special care so that the resulting concrete surfaces require a minimum
finish.
6.3
MOULD OIL :
Care shall be taken to see that the faces of formwork coming in contact with concrete are
perfectly cleaned and two coats of mould oil or any other approved material applied
before fixing reinforcement and placing concrete. Such coating shall be insoluble in
water, non-staining and not injurious to the concrete. It shall not become flaky or be
removed by rain or wash water. Reinforcement and/or other items to be cast in the
concrete shall not be placed until coating of the forms is complete. Adjoining concrete
surfaces shall also be protected against contamination from the coating material.
6.3.1
6.4
WIRE TIES :
Wire ties passing through the walls shall not be allowed. In their place bolts passing
through sleeves shall be used.
6.5
REUSE OF FORMS :
Before reuse, all forms shall be thoroughly scraped, cleaned, nails removed, holes,
suitably plugged and joints examined and when necessary, repaired and the inside
surfaces retreated to prevent adhesion, to the satisfaction of ENGINEER. Warped lumber
shall be resized. CONTRACTOR shall equip himself with enough formwork to complete
the job in the stipulated time.
6.6
REMOVAL OF FORMS :
CONTRACTOR shall record on the drawing or a special register, the date on which the
concrete is placed in each part of the work and the date on which the shuttering is
removed therefrom.
Under no circumstances shall forms be struck until the concrete reaches a strength of at
least twice the stress due to self weight and any construction/erection loading to which
the concrete may be subjected to, at the time of striking formwork, as directed by
ENGINEER.
In normal circumstances (generally where temperatures are above 20 deg. C), forms may
be struck after expiry of the following periods :
a) Walls, columns and vertical sides of
beams.
b) Slabs (Props left under)
24 to 48 hours
ENGINEER.
3 days
7 days
as
directed
by
the
Tie rods, clamps, form bolts, etc. which must be entirely removed from walls or similar
structures, shall be loosened not sooner than 24 hours nor later than 48 hours after the
concrete has been deposited. Ties, except those required to hold forms in place, may be
removed at the same time. Ties withdrawn from walls and grade beams shall be pulled
towards the inside face. Cutting ties back from the faces of walls and grade beams shall
not be permitted.
For liquid retaining structures, no sleeves for through bolts shall be used, nor shall
through bolts be removed. The bolts, in this case, shall be cut at 25 mm depth from the
surface and then the hole shall be made good by sand cement mortar of the same
proportion as that of concrete, just after striking the formwork.
7.0
REINFORCEMENT :
7.1
SUPPLY :
Reinforcement bars shall be High Yield Strength Deformer bars (TMT) Fe 415 Grade as
per latest edition of IS 1786. Wire mesh or fabric shall be in accordance with I.S. 1566.
Substitution of reinforcement will not be permitted except upon written approval from
ENGINEER.
STORAGE :
7.2
The reinforcement shall not be kept in direct contact with the ground but stacked on top
of an arrangement of timber sleepers or the like.
If the reinforcing rods/bars have to be stored for a long duration, they shall be coated
with cement wash before stacking and/or be kept under cover or stored, as directed by
ENGINEER. Fabricated reinforcement shall be carefully stored to prevent damage,
distortion, corrosion and deterioration.
All reinforcement shall be clean, free from grease, oil, paint, dirt, loose mill scale, loose
rust, dust, bituminous material, or any other substances that will destroy or reduce the
bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective
rods shall not be used. All bars shall be rigidly held in position before concreting. No
welding of rods to obtain continuity shall be allowed, unless approved by ENGINEER.
7.3
7.4
LAPS :
Laps and splices for reinforcement shall be as shown on the drawings. Splices in adjacent
bars shall be staggered and the locations of all splices, except those specified on the
drawings, shall be approved by ENGINEER. The bars shall not be lapped unless the
length required exceeds the maximum available length of bars at site.
BENDING :
Reinforcing bars, supplied bent or in coils, shall be straightened before they are cut to
size. Straightening of bars shall be done in cold and without damaging the bars. This is
considered as a part of reinforcement bending fabrication work and contractors rates are
deemed to include this work.
All bars shall be accurately bent according to the sizes and shapes shown on the detailed
working drawings. They shall be bent gradually by machine or other approved means.
Reinforcing bars shall not be straightened and rebent in a manner that will injure the
material; bas containing cracks or splits shall be rejected. They shall be bent cold.
Bars incorrectly bent shall be used only if the means used for straightening and
7.5
7.6
rebending be such as shall not, in the opinion of ENGINEER, injure the material. No
reinforcement shall be bent when in position in the work without approval, whether or not
it is partially embedded in hardened concrete. Bars having kinks or bends other than
those required by design shall not be used.
FIXING :
Reinforcement shall be accurately fixed by any approved means and maintained in the
correct position shown in the drawings by the use of blocks, spacers and chairs as per
I.S. 2502 to prevent displacement during placing and compaction of concrete. Bars
intended to be in contact at crossing points shall be securely bound together at all such
points with 16 gauge annealed soft iron wire. The vertical distances required between
successive layers of bar in beams or similar members shall be maintained by the
provision of mild steel spacer bars at such intervals that the main bars do not perceptibly
sag between adjacent spacer bars.
COVER :
Clear concrete cover for reinforcement shall be maintained as stated on drawings.
The correct cover shall be maintained by cement mortar blocks or other approved
means. Reinforcement for footings, grade beams and slabs on subgrade shall be
supported on precast concrete blocks as approved by ENGINEER. The use of pebbles or
stones will not be permitted.
The 28 days crushing strength of cement mortar cubes/precast cover blocks shall be at
least equal to the specified strength of concrete in which these cubes/blocks are
embedded.
7.7
INSPECTION :
8.0
Erected and secured reinforcement shall be inspected and approved by ENGINEER prior
to placement of concrete.
EMBEDDED PARTS ENCASED IN CONCRETE :
Embedded parts to be encased in concrete shall be unpainted. The encasing shall be
done in concrete with 10 mm maximum size aggregate.
9.0
GROUTING :
9.1
STANDARD GROUT :
The proportions of grout shall be such as to produce a flowable mixture consistent with
minimum water content and shrinkage. The grout proportions shall be as specified on
drawings and as directed by ENGINEER.
a) Sand shall be such as to produce a flowable grout without any tendency to segregate
:
b) Surfaces to be grouted shall be thoroughly roughened and cleaned of all foreigh
matter and laitance.
c) Prior to grouting, the hardened concrete surfaces to be grouted shall be saturated
with water.
Forms around base plates shall be reasonably tight to prevent leakage of the grout.
Adequate clearance shall be provided between forms and base plate to permit grout to be
worked into place properly.
Grouting, once started, shall be carried out quickly and continuously to prevent
segregation, bleeding and breakdown of initial set. Grout shall be worked from one side
of one end to the other to prevent entrapment of air. To distribute the grout and to
ensure more complete contact between base plate & foundation and to help release
entrapped air, link chains can be used to work the grout into plate.
9.2
Grouting through holes in base plates shall be by pressure grouting. Variations in grout
mixes and procedures shall be permitted if approved by ENGINEER.
INSPECTION :
All materials, workmanship and finished construction shall be subject to the continuous
inspection and approval of ENGINEER.
All materials supplied by CONTRATOR and all work or construction performed by
CONTRACTOR immediately replaced at no additional expense to the OWENR and to the
entire satisfaction of the ENGINEER.
Approval of any preliminary materials or phase of work shall in no way absolve the
CONTRACTOR from his responsibility of supplying concrete and/or producing Finished
concrete is accordance with the specifications and drawings.
9.3
All concrete shall be protected by the CONTRACTOR against damage until finally
accepted by the OWNER or his representative.
CLEAN-UP :
Upon the completion of concrete work, all forms, equipment, construction tools,
protective coverings and any debris resulting from the work shall be removed from the
premises.
All the debris i.e. empty containers, scrap wood, etc. shall be removed daily, as directed
by ENGINEER.
The finished concrete surfaces shall be left in a clean condition to the entire satisfaction
of the ENGINEER.
GROUP-3 : BRICK WORK AND UNCOURSED RUBBLE MASONRY WORK
1.0
BRICKS :
Bricks used in works shall conform to the relevant Indian Standards. They shall be sound,
hard, homogenous in texture, well burnt in kiln without being vitrified, table moulded,
deep red, cherry or copper coloured, of regular shape & size shall have sharp & square
edges and parallel faces. The bricks shall be free from pores, chips, flaws or humps of any
kind. Bricks containing unground particles and/or which absorb water more than 15% of
their weight when soaked in water for twenty-four hours shall be rejected. Overburnt or
under-burnt shall be liable to rejection. The bricks shall give a clear ringing sound when
struck and shall have a minimum crushing strength of 75 K/sq.cm., unless otherwise
noted on drawings. The classes and quality requirements or bricks shall be as laid down
in IS : 1077.
The size of the brick shall be 23.0 x 11.5 x 7.5 cm, unless otherwise specified, but
tolerance of up to plus 3 mm in each direction shall be permitted. However, bricks
conforming in size stated in IS : 1077 could be used. Bricks shall be provided with frogs.
Only full size bricks shall be used for masonry work. Brickbats shall be used only with the
permission of the ENGINEER to make up required wall length or for bonding. Sample
bricks shall be submitted to the ENGINEER for approval and bricks supplied and used in
works shall conform to the approved samples. Brick samples shall be got tested as per IS
3495 by the CONTRACTOR at no extra cost to OWNER. Bricks rejected by ENGINEER
shall be removed from the site of works within 24 hours.
Specification of sand used for brickwork shall be same as that specified for concrete work
shall belong to Grading Zone-II.
2.0
MORTAR :
Mortar for brick masonry shall be prepared as per IS : 2250. Mix for cement mortar shall
be as specified in the respective items of work. Gauge boxes for sand shall be of such
dimensions that one complete bag of cement containing 50 kgs. of cement forms one
unit. Sand shall be free from clay, shale, loam, alkali and organic matter and shall be of
sound, hard, clean and durable particles. Sand shall be approved by ENGINEER. It shall
be thoroughly washed until it is free of any contamination.
For preparing cement mortar, the ingredients shall first be mixed thoroughly in dry
condition. Water shall then be added and mixing continued to give a uniform mix of
required consistency. The mortar shall be thoroughly mixed and the same shall be used
within 25 minutes of mixing. Mortar left unused beyond the above specified period shall
not be used in work and shall be rejected.
The CONTRACTOR shall arrange for test on mortar samples, if so directed by the
ENGINEER. Retempering of mortar will not be permitted.
3.0
WORKMANSHIP :
All bricks shall be thoroughly soaked in clean water for at least one hour immediately
before being laid. The cement mortar for brick masonry work shall be as specified in the
respective item of work. For laying bricks a layer of mortar shall be spread over the full
width of the length of the lower course. Each brick shall be pressed into the mortar and
shoved into final position so as to embed the brick fully in mortar. Bricks shall be laid with
frogs uppermost.
4.0
5.0
CEMENT POINTING :
The joints of masonry shall be raked at least 12 mm deep. The dust shall then be brushed
out of the joints and the wall washed with water.
The mortar shall consist of surkhi mortar in proportion of 1:2. This mortar shall be filled
into joints and well pressed with special steel trowels. The joints shall not be touched
again after it has once begun to set.
The joints of the pointed work shall be neat. The lines shall be regular and uniform in
breadth and the joints shall be flat as directed. No false joints shall be allowed.
The work shall be kept wet for seven days after the pointing is complete.
GROUP-4 : MECHANICAL
SUPPLY FABRICATION AND ERECTION OF STRUCTURAL STEEL
1.0
SCOPE :
This section covers the general requirements for supply of steel material, where
specified, fabrication and delivery at site of structural and miscellaneous steelwork.
2.0
IS : 808
2.
IS : 814
3.
IS : 823
4.
IS : 919
5.
IS : 1161
6.
IS : 1363
7.
IS : 1367
8.
IS : 1369
9.
IS : 1852
10.
IS : 2062
11
IS : 2074
12
IS : 4353
b) CODES OF PRACTICE :
1
IS : 800
IS : 8060
IS : 816
3.0
STEEL SUPPLIED BY THE CONTRACTOR :
The CONTRACTOR shall furnish to the ENGINEER duplicate copies of all mill orders covering
the material ordered by him for this project and the test reports received from the Mills for
the ENGINEERs check and information.
If mill tests reports are not available for any steel materials the same shall be got tested by
the CONTRACTOR to the ENGINEERS satisfaction to demonstrate conformity with the
relevant specification.
Unidentified stock material may be used, only with the prior permission from the
ENGINEER in writing, for short sections at locations specifically selected by the ENGINEER
and also for connections where, in the opinion of the ENGINEER, the quality of such
materials would not adversely affect the strength and / or durability of the structure. The
ENGINEER may also permit use of such materials for other works, if adequate random
samples taken out and tested demonstrate conformity with specification and requirement
for the work for which these materials are proposed to be carried out.
4.0
SUBSTITUTIONS :
Wherever the CONTRACTOR, in order to accommodate his / others materials in stock,
desires to substitute structural steel or plates for the sizes shown on drawings, such
substitutions shall be made only after authorisation in writing is given by the ENGINEER.
The ENGINEER may also direct the substitution to be made, when he considers that such
substitutions are necessary.
5.0
FABRICATION :
5.1
GENERAL :
All workmanship and finish shall conform to IS : 800 . All materials shall be finished
straight as per the tolerance limits as specified. All holes and edges shall be free of burrs.
Shearing and chipping shall be neatly and accurately carried out and all portions of work
exposed to view shall be neatly and accurately done and finished. Material in the shops
shall be kept clean and shall be protected from damage.
5.2
CONNECTIONS :
Shop connections shall be effected either by welding, or bolting, as specified on the drawings.
Bolts shall be in accordance with specifications.
5.3
STRAIGHTENING :
Rolled material, before being worked, shall be straightened. If straightening or flattening is
necessary, it shall be done by methods that will not injure the material. Heating and/or
forging shall not be permitted for straightening.
5.4 CUTTING :
Cutting may be carried out by shearing, cropping or machine flame cutting, if permitted by
the ENGINEER. All re-entrant corners shall be shaped notch free to a radius of at least 12
mm. Sheared or cropped edges shall be dressed to a neat workman like finish and shall be
free from distortion and burrs. The kerf on machine flame cut edges shall be removed.
Hand flame cutting shall be undertaken only if so permitted by the ENGINEER and shall only
be carried out by an expert in such work. Hand flame cut edges shall be ground smooth and
straight.
Edge planing of sheared, cropped or gas cut edges is not intended, unless the sheared,
cropped or gas cut edges are such as to warrant it, or is specifically called for.
5.5
WELDING :
Electrodes for shielded-arc manual welds shall comply with the requirements of IS : 814 and
shall be of approved make.
The electrodes for manual arc welding shall be suitable for use in the position and type of
work, as laid down in the above specifications and type of work, and as recommended by the
manufacturers. Electrode classification group 1 or 2 as given in IS : 814 shall be used for
welding steel conforming to IS : 2062.
All welds shall be made by only welders and welding operators who have been properly
trained and are qualified by tests and to perform the type of work required as prescribed in
the relevant applicable standards.
All welds shall be free from defects like blow holes, slag inclusions, lack of penetration,
undercutting, cracks, etc. All welds shall be cleaned of slag or flux and show uniform sections,
smoothness of weld metal, feather edges without overlap and freedom from porosity.
5.6
TOLERANCES :
The dimensional and weight tolerance for rolled shapes shall be in accordance with IS : 1852.
The acceptable limits for straightness (slope and camber) for rolled or fabricated members
are :Struts and columns L/1000 or 10 mm whichever is smaller
For all other members not primarily
in compression such as purlins, girds,
bracings and the web members of trusses
and latticed girders.
L/500 or 15 mm whichever is
smaller
5.8
HANDRAILS :
Handrails shall be provided on open sides of platform, stairways and landings as shown on
drawings. Handrails shall be of standard weight mild steel pipe of flush welded construction,
ground smooth, provided with double rail, top rail about 1 metre above platform level and
pipe posts spaced as shown on drawings.
Smooth uniform curves and bends shall be provided at stair return and also wherever
required / specified. Posts connected to curb plates shall have a neat closure at the a bottom
and 6 mm. Thick plate neatly welded to posts for attachments to curb plate. All necessary
fittings including inner dowels at splices, brackets, bolts, bends, flanges and chains, where
required shall be furnished by the CONTRACTOR. Open ends of all the pipe posts shall be
plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all
points of direction changes in the handrail.
The rate quoted for handrails shall be as per running metre of completed handrailing
including posts, fitting, etc. It shall be clearly understood that individual lengths of runners,
posts, etc. will not be measured for purposes of payment.
6.0
ERRORS :
Any error in shop work which prevents proper assembling and fitting up of parts in the field by
moderate use of drift pins or moderate amount of reaming will be classified by the ENGINEER
as defective workmanship. All charges incurred by the ENGINEER either directly or indirectly
because of the poor workmanship will be deducted from the amount due to the CONTRACTOR
before payments made. The amount of such deduction will consist of the sum total of the
costs of labour direct or indirect, material, plant, transportation, equipment rental and
overhead expenses. In case the ENGINEER choose to reject the material because of poor
workmanship, the cost of all handling and returning the material to the CONTRACTOR, if he
so desires, shall entirely be to CONTRACTORs account. All the replacement materials shall
conform to the same specification as for the original materials, & shall be supplied free and in
all such cases, the cost of handling, transport and delivery to site shall be borne by the
CONTRACTOR.
7.0
PAINTING :
All fabricated steel material, except those galvanised, shall receive protective paint coating.
The surface of steelwork to be painted shall be thoroughly cleaned of all loose mill scale,
rust, grease, dirt and other foreign matter by hand tool cleaning, power tool cleaning or
flame cleaning as specified and as directed. In power brushing, sufficient care shall be
exercised not to burnish mill scale to a slick finish to which paint may not adhere properly.
The paint treatment specified shall be applied either by brushing or spraying on the
thoroughly cleaned and dry surface. Airless spraying shall be done if so specified. Surfaces
inaccessible after assembly shall receive an additional coat of the specified paint prior to
assembly.
Paint shall be stirred frequently to keep the pigment in suspension. All paint delivered to the
fabrication shop shall be ready mixed in original sealed containers as packed by the paint
manufacturers and no thinners shall be permitted. No painting shall be done in frosty/foggy
weather or when the humidity is high enough to cause condensation on the surface to be
painted. Paint shall not be applied when the temperature of the surface to be painted is 45
deg. or higher.
8.0
8.1
SCOPE :
This section covers the specific technical requirements for the following:a) Supply, inspection, and testing at site of tubular structural steelwork.
b) Fabrication, erection and testing at steelwork.
8.2
9.0
WELDING :
Tack welds used in assembling tubes shall be made by a qualified welder. Tack welds which
are not to be removed shall be made with an electrode which is the same as or equivalent to
the electrode to be used for the first pass.
All welds shall be full penetration, welds and homogenous with no voids. Any cracks or
blowholes that appears on the surface of joint shall be removed by chipping.
All stipulations for welding work as mentioned in this specification (para 6.6) shall apply for
the welding of tubular steelwork, in addition to that mentioned above.
GROUP - 5
SPECIFICATION FOR BULLET MOUND MATERIALS
1.0
2.0
2.1
Murrum / sand as specified shall be used for the ground improvement work.
The quality of MURRUM shall be strictly as approved by HPCL and the decision of HPCL in
this regard will be final and binding on the contractor. Murrum shall be laid in layers, each
layer in loose state shall not be more than 200 mm in thickness. Water as per OMC
requirement shall be sprinkled on the layer and after allowing for soaking, compaction
shall be done using a vibro roller ( 10 MT static weight) of 20 MT - 30 MT weight in
dynamic state. The layer shall be compacted to obtain a degree of minimum 98% with
respect of the max. Dry density ( Modified Proctor density ) determined in the lab under
Optimum Moisture Content ( OMC ) condition. Each layer shall be tested for compaction
at rate of 1 test per every 500 Sqm area. Each test shall consists of 6 samples. Contractor
shall bear the cost of all laboratory and field tests for the job.
2.2
The sand to be used for ground improvement shall be as per clause 2.4 below. The quality
of sand shall be strictly as approved by HPCL and the decision of HPCL in this regard will
be final and binding on the contractor.
2.3
The geo-textile layer (Terram 1,000 or equivalent approved quality) shall be laid directly
on the top of the murrum layer prior to the commencement of the sand bed preparation
work as per the approved drawings.
2.4
The bullet bed material shall be sand laid in layers, each layer in loose state shall not be
more than 300 mm in thickness so as to give compacted thickness of 200-250 mm.
Water to the tune of 3 to 5 lit/ sq.m. shall be sprinkled on the sand layer and after
allowing for soaking, compaction shall be done using a vibro roller (10 MT static weight)
of 20 MT-30 MT weight in dynamic state. The layer shall be compacted to obtain a
degree of compaction of minimum 98% with respect to vibrated dry density of sand
determined in lab. The required sand filling shall be completed in layers as above to reach
the desired level up to the bottom of the bullets. (Ref BS: 1377 1900 Part 4, Clauses 3.3
and 3.4.)
2.5
The sand bed shall be laid to the falls & to the levels and full depth as shown on the
drawings and the bed for the bullets shall be excavated out of the fully compacted bed
using a template formed to the exact shape and size of the bullets.
2.6
If welding trenches are to be used they shall be backfilled with sand and compacted in
accordance with the above clauses. The trenches shall be adequately propped and braced
to ensure that there is no loss of compaction of the adjacent sand bed.
3.0
3.1
The sand surround to each bullet shall be material in compliance with clause 5.2 laid
around the bullets during the mound filling operation to a 300 mm minimum thickness
and shall be hand compacted into position.
3.2
Filling material between bullet surrounds shall be sand in compliance with clause 5.2 laid
in maximum 200 mm layers, or other suitable material.
3.3
Sand filling placed between bullets and a line extending out at 45 from the enter of the
bullet above the bullets enter line shall be hand compacted and fill placed outside this
line shall be light machine compacted (both to minimum of 93% maximum dry density).
Compaction shall be sufficient to avoid significant settlement of the sand filling/mound
surface but shall be such as not to impose undue stresses on the bullets.
3.4
3.5
The sand filling shall be placed equally, in maximum 200 mm layers (uncompacted
depth), on each side of the bullets so as to avoid any lateral displacement/rotation of the
bullets during compaction.
3.6
Sand filling shall be brought up to the levels and slopes as denoted on the drawings to
below the drainage layer.
4.0
4.1
A 1,000 micron UPVC membrane shall be laid on top of the compacted sand fill, to falls
and levels denoted on the drawings, with a 1m minimum lap at joints and with the higher
sheet overlapping the lower sheet.
4.2
A geo textile membrane of Terram 1,000 or equivalent (to be approved by HPCL / TPIA)
shall be laid on top of the UPVC membrane to protect it from the stone layer laid above
this membrane.
4.3
A perforated PVC drain pipe shall be laid as denoted on the drawings, between the Terram
and the UPVC membrane and shall be surrounded by pea gravel and overlain by a 5 mm
to 50 mm stone layer. The PVC drainage pipe shall conform to BS 4962:1989, whereas
the drainage pipe shall conform to BS:5911.
5.0
MATERIAL SPECIFICATION
5.1
The sand fill required for ground development shall be as per Clause 5.2 below.
5.2
The sand for the bullet bed, bullet surround and filling between bullets shall consist of
material complying with the following specification :a) Good quality clean, non-aggressive sand with a maximum organic Material
Content of 3% by weight.
b) A max. silt content of 10% by weight (particles smaller than 0.063 mm).
c) A maximum particle size of 5 mm.
d) A grain size distribution Uniformity Coefficient (D60/D10) of between 2 & 8
5.3
The pea gravel shall consist of clean washed, single sized, 8mm round stone free from all
organic matter, sulphates or any other deleterious material and laid as surround to the
perforated PVC drain pipe, minimum 150 mm thickness.
5.4
The stone layer to the top of the mound shall consist of clean, well graded stone free from
all organic material, sulphates, or any other deleterious material, and with a particle size
of 5mm to 50mm. Depth varies from 150 mm minimum to 350 mm maximum.
5.5
The side slopes to the mound shall be protected by good quality stone pitching
constructed out of stones of size 225 average and grouted together to form an
impermeable finish, all as denoted on the drawings with 1:4 cement mortar for joints.
Raised pointing of pitching is to be carried out with 1:2 cement mortar.
6.0
SUMMARY TABLE
6.1
A summary of the proposed materials, grading and compaction requirements for the
bullet mound is given in the following
Table 6.1.
ITEM
Fill to underside of
sand bed
Bullet sand bed
GRADING
COMPACTION
Clean Sand to
98% of max. laboratory dry density,
5.2
Clean sand to
98% of max. laboratory dry density,
Clause 5.2
Bullet sand surround, Clean sand to
Hand compacted to minimum
300 mm
Clause 5.2
93% max. laboratory dry density.
Mound filling between Clean sand to
Hand compacted or light machine
bullets
Clause 5.2 or
compacted to minimum 93% max.
other suitable
laboratory dry density.
Material
Pea Gravel
Clean stone to
N/A
Clause 5.3
Stone Drainage Layer Clean stone to
N/A
Clause 5.4
Stone Pitching
Stone to Clause
N/A
5.5
NOTE: Contractor shall submit the Quality Assurance plan for the Entire mounded bullets
construction
MATERIAL
TESTS
Water
Cement
a) Ph value
b) Limits of Acidity
c) Limits of Alkalinity
d) Percentage of solids
e) Chlorides
f) Suspended matter
g) Sulphates
h) Inorganic solids
i) Organic solids
(a) Fineness
(b) Soundness
(c) Setting time ( Initial &
Final )
(d) Compressive strength
(e) Consistency
(a)Particle Size
distribution
(b) Sp. Gravity
(c) Deleterious substance
(d) Organic impurities
(e) Water absorption
(f) Fineness modulus
(a) Percentage of soft /
deleterious material
(b) Particle Size
distribution
(c) Organic impurities
(d) Sp. Gravity
(e) Bulk density
(f) Aggregate crushing
strength
(g) Aggregate impact
value
(h) Alkali Reactivity
(i) Flakiness index
(a) Physical properties
(b) Chemical test
Sand
For
concreting
4.
Coarse
aggregate
For
concreting
Reinforce
ment steel
TEST
PROCED
URE
I.S.
3025
ACCEPTANCE
CRITERIA
PERIODICITY
I.S. 456
I.S.
4031
I.S. 8112 /
12269
IS 2386
IS 383
Zone - II
I.S.
2386
I.S. 383
Manufacturers test
certificate and Lab
test for each batch
brought to site.
Every 40 Cum or
part thereof.
Every 40 cum or
part thereof
I.S.
1608
I.S. 1786
Concrete
For PCC>
M10
Cement
concrete
(For RCC)
Sand for
filling
I.S.
1199
I.S. 456
I.S.
1199
I.S. 456
I.S.
2386
Every 5 cum
Qty.
I.S.
2720
Max. organic
content 3% by
wt.
Silt content
10% by
weight
Particle size
max. 5mm
Uniformity
coefficient 2.0
to 8.0
Compaction
as per PO
specs.
No. of
Samples
1-5
M3 : 1
6-15 M3 : 2
16-30 M3 : 3
31-50 M3
:
4
51& above: 4 plus
one additional
sample for each
additional 50 M3 or
part thereof.
One lab test for
each source or as
per direction of
Engineer-in-charge
Field compaction
test:
1 test for 500 M2
area of each layer.
There shall be min.
10 density
measurements for
each test.
TECHNICAL SPECIFICATIONS
FOR
ELECTRICAL WORKS
SCOPE :
This specification covers the design, manufacturing and supplying of PMCC & MLDB
required by M/s HINDUSTAN PETROLEUM CORPORATION LIMITED for their Consumer
Facility at M/s, BAMUL, Bengaluru.
2.0
The
scope
of
work
shall
cover
the
design,
fabrication,supply,testing,commissioning of PMCC panel.
The equipment shall be suitable for 415 V, 50 Hz, 3 phase power supply & for an
ambient temperature oupto 55 deg C and relative humidity of 100%. The PMCC
panel shall be of Double Front Type & the main Bus Bar shall be rated for
1000A. The vendor should submit four sets of drawings for approval to HPCL
before taking up the manufacturing of the PMCC Panel.
SPECIFICATIONS:
I.
INCOMING FEEDERS:
Nos
Nos
Nos
Nos
Nos
Nos
The outgoing feeders shall have the minimum requirements as detailed below:
i.
ii.
1 No TP SFU with HRC fuses, links & bases suitable for the feeder
specified.
1 No suppressed scale ammeter with selector switch along with 1 nos CTs
of 15VA class I accuracy.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
METEOROLOGICAL DATA
Ambient temperature
Humidity
: 50 deg C ( Max.)
: 100% ( Max.)
DEVIATIONS
Any deviations in the equipment offered shall be clearly brought out in the offer. In
the absence of the same, it will be presumed that the equipment offered is in
compliance with the specification.
5.0
COMPLETENESS OF OFFER:
Offer must be complete giving all the required data & necessary drawings.
6.0
QUANTITY
1. Power & Motor Control center(PMCC) & MLDB
7.0
1 No
STANDARDS:
All materials, equipments and accessories used in the manufacture shall conform
to the latest editions of relevant Indian / British standards including amendments
and addenda, some of which are listed below:
1. IS 375 : Marking and arrangement for switchgear bus bars, main connection and
auxiliary wiring.
2. IS 722 : A.C.Electric Meters
3. IS 1248 : Direct acting electrical indicating instruments
4. IS 2147 : Degree of Protection provided by enclosures for low voltage switchgears.
5. IS 13947.1 : Low voltage switch gear & control gear General rules 1993
IS 13947.2 : Low voltage switch gear & control gear Circuit breakers 1993
IS 13947.3 : Low voltage switch gear & control gear Switches, Disconnectors,
Fuse Combination units 1993
IS 13947.4 : Low voltage switch gear & control gear Electro Mechanical
Contactors and motor starters 1993
IS 13947.4 : Low voltage switch gear & control gear Control Circuit Devices &
Switching elements 1993
6. IS 12703 : Low Voltage Fuses { Part 1:2:4 (rev 0)}
7. IS 2705 : Current Transformers
8. IS 3156 : Voltage Transformers
9. IS 3231 : Electric relays for power system protection
10. IS 3202 : Code of practice for climate proofing of electrical equipment.
11. IS 3427 : Metal closed switch gear and control gear.
12. IS 4237 : General requirements for switchgear and control gear for voltage not
exceeding 1000 volts.
13. BS 162 : Specification for electric power switchgear and associated apparatus
14. IS 8623 : Factory built assemblies of switchgear and control gear.
15. IS 694 Part I & II : PVC insulated cables( for voltage upto 1100 V with copper and
aluminium conductors)
16. IEC 255-1-0 : Specification for Electronic Timers
In the absence of specific Indian Standard Specifications, International Electro
Technical Committee specifications shall be followed.
8.0
8.1
The PMCC & MLDB shall be floor mounted, double front and totally enclosed to
make it dust and vermin proof.
8.2
Switch boards shall be fabricated from 14 swg CRCA sheet steel minimum.
The base frame of the panels shall be made from ISMC 100 and a min angle
section of 75x40x6mm to be provided at the bottom of each cabinet.
14 SWG MS sectionalized entry plates shall be provided for multi core entries and
6 mm hylam sheet for single core entry points.
The height of all panels shall not be more than 2000 mm and the depth of the
panel shall not be more than 500 mm for single front and 800 mm for double front
except for the circuit breaker panels, where the depth could be about 1000 mm.
The circuit component shall be mounted on sectionalized 12 SWG 2.5mm thick MS
sheets with suitable threading in the sheets to facilitate easy maintenance, future
addition etc.,
Switchgear shall be floor mounted, free standing, totally enclosed and dust, damp
& vermin proof. Non deteriorating gaskets to be used between all adjacent units
and beneath all covers and doors of dust proofing.
The switchgear panels shall have minimum IP-52 degree of protection. (as per IS
2147)
Hinges provided for doors shall not be visible from front.
Switchgear shall be self ventilated.
8.3
8.4
Switch boards shall comprise of a number of vertical panels of same height and
bolted together to form PMCC/MLDB.
Clearance between phases & between phase and earthing as well as the insulation
levels shall be in accordance with relevant IS/BS.
8.4(a) Switch gear construction, mounting of various equipments viz., circuit breakers,
instruments, relays, bus bars and secondary wiring shall be done with due
considerationto the following:
i.
ii.
iii.
iv.
v.
vi.
vii.
8.5
8.6
Bus bars:
There shall be 3 nos of bus bars for phases & 1 no for neutral. These shall be of
Electrical Grade Aluminium and of sufficient cross section to carry rated current
without any damage. The bus bars shall be supported on epoxy resin cast insulators
and covered by heat shrinkable PVC with colour coded sleeves. The main bus bars
shall be rated as indicated in the single line diagram and suitable for extension on
both
sides.
Two separate sets of vertical bus bars should be provided for the front and rear
modules in double front switchboards.
Tapping points shall be treated against oxidation and shall be insulated in a similar
manner to the main bus bars. Appropriate identification markings/labels shall be
provided on the bus bars and tappings for distinguishing the various phases and
neutral. Bus bars shall be air insulated, enclosed having barriers / covers.
CAUTION LIVE BUS BAR board shall be provided on barriers/covers.
8.7
Outgoing feeder modules shall be of fixed type. Incomer ACB feeders shall be of
fully draw out type and shall be provided with mechanical & electrical interlock.
8.8
8.9
Provision shall be made to ensure that compartment door cannot be opened when
the feeder switch /ACB is ON. The cables shall be neatly clamped in the cable alley
so that disconnecting the cables from the terminals can be done easily.
8.10
Fabricated panel shall undergo 7 tank pre treatment of degreasing, pickling &
phosphating etc., two coats of Zinc chromate primer and two coats of epoxy based
paint of approved shade shall be applied.
Equipments inside the compartment shall be arranged in a logical manner for ease
of reference at site. The equipment reference mentioned in wiring diagram shall be
provided on the equipment.
8.13
Cable shall be terminated at bus bar extensions back of the panel for incomer or
large diameter cables and at stud type terminal blocks in the cable alley for other
out going power feeders and clamp type terminals for control cables. The terminal
block shall be identified with feeder number. Minimum distance between gland
plate and termination shall be approximately 200 mm.
8.14
Removable un drilled gland plates for the panel shall be provided complete with
gaskets, nuts and bolts for proper fixing.
8.15
8.16
Control supply voltage will be 230 V AC and shall be derived by tapping phase and
the neutral from the incoming side of the SFUs
8.17
One Green, red and one amber indicating lamps of LED type shall be provided on
each starter feeder for OFF, ON & TRIP indication in PMCC.
8.18 Only stop (stay put) and reset push button shall be provided on the starter door.
8.19
All starters upto 22 KW shall be of DOL type and 22 KW and above shall be star
delta type.
8.20
Each panel shall be provided with space heaters ( min 2 nos x 75 watts each) shall
be provided for panel heating, operating on 230V AC and controlled by thermostat,
toggle switch, fuses etc.
9.0
9.1
The circuit breaker including its operating mechanism with equipment shall be
mounted on trolley / carriage moving on guides designed to align correctly and
allow smooth movement.
9.2
Incoming and out going power connections for each draw out cubicle between
fixed portion of the panel and trolley shall be by means of self aligning plug in
contacts. Both male and female contacts shall be of silver plated copper. Contact
design shall ensure adequate pressure normally and increase in contact pressure
during short circuit.
9.3
Control wiring connection between trolley and fixed part of panel shall be made by
sliding type terminals, preferably in the front of circuit breaker so that
inspection/testing is easy.
9.4
The draw out design shall have three positions SERVICE, TEST, and ISOLATE
for circuit breaker and motor starter feeders. For switch fuse feeders, only
SERVICE and ISOLATE positions shall be provided.
9.5
Position indicator shall be provided on the service panel to indicate the position of
the C, B trolley viz., SERVICE, TEST, and ISOLATE.
9.6
In the TEST position, it shall be possible to check the feeder operation without
energizing the power circuit.
9.7
It shall be possible to withdraw the circuit breaker trolley up to the TEST and
ISOLATE position without opening the front door.
9.8
Automatic safety shutters shall be provided in all CB panels for all openings which
will provide access to the live parts of the switchgear upon withdrawal of any
portion of the switchgear components parts.
9.9
There shall be provision for locking the trolley in all the three positions for
complete safety.
9.10
Feeder compartments shall be totally closed from all sides with door on the front
side.
9.11
The draw out portion of the cubicles shall be effectively connected to the earth bus
through scraping contacts. It must be ensured that the draw out portion gets
earthed before the feeder moving contacts are plugged into stationary contacts in
service position.
9.12
9.13
Compartment door of breaker shall not open unless breaker is in open position.
9.14
Automatic safety shutters shall be provided to cover live contacts when carriage is
withdrawn.
9.15
9.16
9.17
10.0
10.1
The switchgear shall have single bus bar pattern with air insulated bus bars
housed in a separate compartment, segregated from all other compartments, with
sheet steel barriers. Bus bars shall be of high conductivity electrolytic copper or
aluminium, suitable for carrying the rated and short time current without over
heating. Bus bars shall be adequately supported on insulators to withstand
dynamic stresses due to short circuits. Maximum bus bar temperature shall not
exceed 85 deg C under normal operating conditions.
10.2
All bus bar connections and bus taps to individual feeders shall be either by means
of 1100/650 V grade PVC insulated wires or links insulated with shrunk PVC
sleeves. Bus bars shall be colour coded for ready identification of three pahses.
10.3
11.0
11.1
The circuit breakers shall be air break type and of horizontal fixed construction
conforming to IS: 13947-2
11.2
Circuit breakers shall be power operated and the closing mechanism of the circuit
breakers shall be motor wound, spring charged with a provision of manual
charging.
11.3
The operating mechanism shall be mechanically and electrically trip free and non
pumping. Anti pumping mechanism shall be built in for safety purpose.
11.4
A mechanical OFF push button suitable for front of board operation and a
mechanical ON-OFF indicator shall be provided. The mechanical ON push
button should be shrouded to prevent inadvertent mal-operation.
11.5
A shut trip coil shall be provided for tripping the circuit breakers. Shunt trip coil
shall be easily accessible from the front of the panel and easily replaceable.
11.6
Provision shall be made for remote closing and tripping of the circuit breakers with
electrically operated mechanism.
11.7
11.8
11.9
Ready to close interlock / indicator shall be provided on the front facia of the
ACB to prevent closing of circuit breaker unless all the suitable parameter for safe
closing are met. For example, under voltage release has to be energized, shunt
release shall be de-energised, breaker should be in connected/test/disconnected
position, spring should be fully charged etc., if these conditions are met, then
Ready to Close indicator should show OK.
11.10
Main contacts shall have adequate contact pressure to carry the rated and short
time current without excessive temperature rise. The contacts shall be inspectable
for wear from the Arc chamber and easily replaceable. In the worst case of main
contact getting welded, it shall be possible to replace them at site.
11.11 The main power contacts shall be silver alloy plated or shall be of suitable material
to minimize erosion of contact due to arcing & anti weld property. The main power
contacts shall be provided with a Contact Erosion Indicator to assess the
healthiness of the contacts for the fault breaking capacity the breaker is rated for.
11.12
11.13
The ACB fault protection unit shall be offered with the following protection as
specified.
- Overload protection : Inverse time delay overload release (40% - 100%
operating current)
- Short circuit protection : ( Instantaneous short-circuit release, short time delay
short circuit current release, short-time-delay short circuit release with definite
time delay for better co-ordination between two ACBs/Fuses) 1.5 to 12 operating
current.
- Earth fault protection with operating time delay(20% to 60% of rated current).
Individual LED for indication of overload, short circuit, earth fault should be made
available on the protection unit.
11.14
MCCB shall conform to IS 13947 2 shall be rated for the short circuit breaking
capacity specified (25 KA) and shall all be of current limiting type.
11.15
MCCB shall be provided with min 1 No+1NC auxiliary contacts rated for 5 A at
240V 1 Ph, 50 Hz AC or 1.3 A at 110 DC(Inductive Load)
11.16
The MCCB should have integral trip free mechanism that prevents the breaker
contacts from being closed should an overload or short circuit occur.
11.17
The accessories eg., under voltage release, shunt trip, auxiliary switch, alarm
contact etc., should be fittable at site. The MCCB shall be line contactable at both
ends to facilitate bus bar connections.
11.18
The MCCB shall be fixed with overload release providing inverse time
characteristics.
11.19
MCCBs shall be provided with solenoid closing mechanism to make them suitable
for remote closing operation. The closing solenoid shall be suitable for specified
control supply voltage.
MCCB operating handle ON and OFF positions shall be displayed and the
operating handle shall be mounted on the door of the compartment housing
MCCB.
12.0
12.1
Switch disconnector fuse shall be of two position (ON/OFF) type, heavy duty (AC
22/23 category as specified), load break, quick make and break type complying
with the requirements of IS 13947-3 and suitable for front of board operation.
12.2
12.3
The switch disconnector fuse unit shall have positive indication of contact
separation.
13.0
FUSES
13.1
All fuses shall be IS 13703, non deteriorating high rupture capacity, DIN type
mounted in suitable switch disconnector units. For control application, BS
type(bottle type) fuse is permissible.
13.2
Fuses for motor feeders (DIN type) shall be so chosen that they do not operate
during starting of the respective motors and shall provide adequate protection for
all feeder components as per type 2 co-ordination conforming to IS 13947-4
13.3
For switch disconnector fuse feeders, the rating of the fuse, if not specified, shall
be same as that of the switch rating.
13.4
Fuses shall be provided with operation indicators and shall be possible to change
fuses with the SDF off but circuit live.
13.5
All fuses in control, indication and metering circuit shall be HRC, link type designed
for continuous operation for an ambient temperature of 55 deg C.
13.6
Insulating fuse pulling handles shall be available for each size of fuse with the
switch gear.
14.0
14.1
Motor starters shall comprise of one main TP isolator, HRC Fuses for power and
control (or MCCB if required), main power contactor/s, auxiliary contactor/s,
bimetallic thermal overload relay, stop/reset push buttons, terminals etc., as
mentioned in the data sheets.
Switch disconnector fuse
Contactors
BMR
Stop push
14.2 Starters shall be direct on-line or automatic star delta type as specified in the data
sheets. Starters shall be of AC 3 utilisation category as specified in IS 13947. Star
delta starters shall be automatic with three contactors and a timer. Reversing
starters shall have forwarded and reverse contactors electrically interlocked with
each other.
14.3
C.B. ON
C.B. OFF
Trip supply supervision
Auto trip
Spring Charged ] when specifically called for
Potential Indication
16.2 Secondary terminals of the CT shall be brought out suitably to a terminal block
which will be easily accessible for testing and for external connections.
Terminals shall be marked in accordance with IS 2705. A rating plate as per IS
2705 shall be provided on each current transformers.
16.3 Current transformers shall preferably be capable of being left open on the
secondary side with the primary circuit carrying rated full load current without
overheating or damage.
17.0 INSTRUMENTS AND RELAYS
17.1 All relays and instruments shall be flush mounting type. The instruments shall
preferably be of the rectangular shape and shall have adequate scale strength.
Protective relays shall be in accordance with the protective scheme specified. All
relays and instruments shall be mounted in dust light, damp proof, tropicalised
cases. Instruments and relays shall be able to withstand a high voltage test of 2000
volts RMS for one minute. Wherever possible, metering instruments and relays shall
be draw out type. Minimum size of indicating instruments will be 144 sq.mm
17.2 Relays shall be provided with hand reset type mechanical operation indicator of
direct acting type or fitted with an auxiliary unit where required. The auxiliary unit
shall be shunt reinforcing, shunt seal in or series seal in type as specified. It shall
also be provided with minimum two parts of self, hand or combined self or hand
reset type contacts if specified.
17.3 CT secondary rating and current setting range of relays shall be as specified in the
drawing. All indicating instruments shall be of Industrial Grade 1 accuracy as per IS
1248 and energy meters as per IS 722.
18.0 CONTACTORS
18.1 The contactors shall be air brake type equipped with three main contacts and
minimum 2 NC & 2 NO auxiliary contacts. The main contacts of a particular
contactor shall have AC 3 rating as shown in the relevant switch board data sheet
for contactor.
18.2 The auxiliary contacts shall be rated for minimum 5 A at 240V AC and 1.3A at 110V
DC ( Inductive load)
18.3 Unless specified otherwise, the coil of the contactor shall be suitable for operation
on 240V 1 Ph AC supply and shall work satisfactorily between + 10 and -15% of the
rated coil voltage.
18.4 The contactor drop off voltage shall be between 15% to 65% of the rated coil
voltage.
19.0 THERMAL OVERLOAD RELAY WITH BUILT IN SINGLE PHASE PREVENTOR
19.1 Thermal overload relay shall be 3 element, positive acting and ambient temperature
compensated type with adjustable setting range & built in single phase preventor.
19.2 Thermal overload relays shall be manually reset type with the reset push button
brought out front of the panel. The reset push button shall be capable of being
operated without opening the component door.
19.3 Thermal overload relays shall be provided with min 1 NO + 1 NC and 1.3 amps at
110V DC (Inductive load)
20.0 RELAYS
20.1 All relays shall be back connected, draw out type, suitable for flush mounting and
fitted with dust tight covers.
20.2 The relay cases shall have provision for insertion of test plugs in the front for testing
and calibration purposes. It shall be possible to test the relays without
disconnecting the wiring and without withdrawing the relay. The insertion of test
plug shall automatically short circuit the CTs and permit extension of external
power supply to the relay.
20.3 The relays shall be provided with hand reset type built in flag indicators. It shall be
possible to reset the flag without opening the relay case.
20.4 Each protective relay shall be provided with min 2 nos. potential free contacts of
required configuration.
20.5 Each tripping relay shall be lock out type with hand reset coil cut off contact. Min 4
nos. potential free auxiliary contacts of required configuration shall be provided for
each tripping relay if the no of contacts are not indicated in the feeder data sheets.
The tripping relay shall be suitable for satisfactory operation from 50% to 110% of
the specified control supply voltage.
21.0 CONTROL AND SELECTOR SWITCHES / CONTROL FUSE AND CONTROL FUSE
BASE
21.1 Control and selector switches shall be of rotary type provided with escutcheon
plates engraved with switch operating positions.
21.2 Selector switches shall have stay put positions with oval handle. The number of
contacts and their operation in each switch shall be as per the requirement
specified in Data Sheets or contact development diagrams.
21.3 The control fuse link carrier shall be of CAM operated type for ease of
maintenance& inspection. It shall be possible to isolate the fuse link/ fuse link
carrier by drawing out the fuse link holder in the extreme draw out position.
21.4 The control fuse base shall be DIN rail mountable for ease of maintenance and
assembly.
22.0 ANNUNCIATORS
22.1 Annunciators when specified in the data sheet/SLD shall have audible alarm and
visual display through translucent plastic window of preferably 50 mm x 65 mm
size engraved with appropriate function in block letters on each window.
27.8 Earth bus bars shall be of tinned copper/alum. with holes but the bolts and nuts
and washers shall be cadmium plated. Earth bus bar shall be provided all around
the cubicle at the bottom and it shall be of the same size as neutral bus bars but
the maximum size will be 50 x 6 mm with duplex external earth connection
arrangement.
27.9 Bi-metallic lugs shall be used wherever copper cables are being terminated on
aluminium bus bars or vice versa.
28.0 PAINTING & FINISHING
All metal works and ,etal parts of the switchboards shall undergo 7 tank pre
treatment of degreasing,pickling in acid,cold rinsing, phosphating, passivating and
then sprayed with 2 coats of Zinc Chromate primer. The finishing treatment shall be
by application of 2 coats of Epoxy based paint of colour as specified.
Primer
Finish Paint
Feeder No.
Equipment reference number and description
Rating (KW/KVA/AMP)
29.3 All components whether mounted inside the switchboards or on the door shall be
permanently and clearly labeled with reference number and/or letter of their
function. (Rating of fuses shall form a part of the fuse designation).
29.4 All labels shall be non corrodible anodized aluminium with white engraved letters on
black back ground. All the letters shall be in capital.
29.5 Labels for feeder panel designation shall be fixed on the front side of respective
panels with chrome plated self tapping, counter sunk head screws. These labels
shall be identical size to permit interchange.
30.0 TESTING AND INSPECTION
After completion of all work at the manufacturers worls for the
panels/switchboards shall be inspected and tests witnessed by the purchasers
representative or TPIA. However, stage inspection may be carried out from time to
time to check progress of work and workmanship.
The following work shall be carried out:
i.
All routine tests specified in relevant Indian Standards shall be carried out
on all circuit breakers.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
Vendor shall provide all facilities such as power supply, testing instruments and
apparatus required for carrying out the tests. Required copies of test certificates for
all the tests carried out along with copies of type test certificates and certificates
from sub vendor for the components procured from them are to be submitted
before dispatch of the switchboards.
Approved TPIA : BVIS/EIL/RITES/IRS/LLOYDS
Note: All routine & acceptance tests as specified by the applicable standard code
shall be conducted. Type test certificates for fault level, certified by CPRI Bhopal
should be submitted along with the bid. The vendor shall also submit a list of
guaranteed technical particulars with the bid.
31.0 DRAWING AND INFORMATION
The vendor to furnish, generally, the following drawings:
i.
ii.
iii.
iv.
v.
Vendor shall furnish 3 copies of above drawings for purchasers review. After final
review, required number of copies and reproducible shall be furnished as final
certified drawings.
The information furnished shall include the following:
i.
ii.
iii.
32.0 TOOLS
One complete set of all special or non standard tools per switchboard required for
installation, operation and maintenance of switchboard shall be supplied.
33.0 SPARES
The price list of recommended commissioning and operating spares shall be
provided along with the technical bids.
34.0 DEVIATIONS
Deviations from the specifications must be stated clearly by the bidder. In the
absence of such a statement, it will be assumed that the requirements of the
specifications are met without exception.
35.0 MAKE OF COMPONENTS
1. Indicating instruments
2. Air Circuit breakers
3. MCCBs
4. CDG relays
5. Contactors/SFUs
6. Push Buttons
7. Indicating lamps
8. Current Transformers
9. BMR
10. Terminals
11. Wires
12. Selector switches
13. KWH meter
14. Electronic timers
15. Fuse switch units
16. HRC Fuses
17. MCBs
18. Automatic change over switch
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
AE/MECO/ENERCON
GE/L&T/Siemens
Siemens/Schneider/GE/L&T
GE/Alsthom
Siemens / L&T
Siemens/Teknic
Teknic/Mathura/Siemens/Vaishno
Indcoil/AE/IMD
Siemens / L&T
Elmex/connectwell
Finolex/Polycab/CCI
Kaycee/ Siemens / L&T
Simco/ ENERCON/ L&T
Siemens/EAPL
Siemens/ L&T/GE
GE/ Siemens / L&T/ Schneider
Siemens/GE/MDS/ L&T/ Schneider
Havells
2.
To provide 230V AC power to ROVs 2 Nos and High Level Alarms 2 Nos through
individual ON-OFF switch. There should be a provision to close the individual ROVs
from the relay box panel through a push button/toggle switch. Also, panel should
have indicators to indicate ROVs open/close status.
3.
It shall have a push button for switching ON the panel. The panel should have
provision for receiving power supply from UPS and distributing through relays to
the instruments on the mounded storage vessels. It should also have provision to
stop all pumps, compressors and vapourisers.
4.
In case of trip signal received from the High Level Alarm, the relay box panel, through
relays, shall immediately close the ROV and also stop all pumps, compressors and
vapourisers. Reset PB shall be provided to reset the power to all contactors &
equipment. There should be a provision to close the ROV and trip all LPG
equipment through a manual push button station on the relay box panel. This ESD
shall also be activated from the field through a FLP push button station located
near the LPG pump house.
5.
The relay box panel shall have the provision to show indication/signal of high level
alarm trip for 2 Nos of LPG storage vessels. The high level alarm & ROVs should be
interlocked in the relay box in such a way that the high level alarm trip signal from a
storage vessel should close the corresponding liquid ROV of the storage vessel.
The following indication shall be provided on the RELAY BOX PANEL
A.
B.
C.
D.
E.
7. An Aluminium earth bar of adequate size shall be provided throughout the length
of the panel. 2 nos. earthing studs shall be taken out for external earthing.
8. Copper bus bar shall be provided inside the panel to receive power from battery
banks and distribute it to the system.
9. The following shall also be provided on the relay box panel in addition to switches,
push buttons, instruments etc., as indicated in the Requirements of Panel
Voltmeter for mains AC Voltage.
Voltmeter for DC Voltage.
Ammeter for current drawn from AC mains.
Ammeter for total DC current.
Ammeter for battery charging current.
Indication for Mains AC ON, DC ON, Control supply to relay box panel ON.
ON, OFF switches for switching on Main AC power & DC power to panel
and also provision to isolate batteries, if required.
HRC fuses for AC incoming & DC power, power supply to all instruments.
Switches for cutting off power supply to any instrument without affecting
the other areas.
Reset push button for timer.
Test position for siren testing.
Accept push button for siren.
:
:
:
:
:
:
:
:
Keycee
IIC/Teknic
Mathura
Indcoil/AE/IMD
Dowells
IMP make
Elmex
Siemens / L&T/GEC
9. Push Buttons
10. Sirens
11. Timers
12. Battery charger
13. Fuse & Fuse Base
14. MCB
: L&T
: Kheraj
: Vendors to specify(preferred make L&T)
:Vendors to specify (SAB-NIFE)
: Siemens / L&T/ English Electric
: MDS/INDO KOPP
a.
b.
c.
d.
e.
f.
g.
h.
i.
2.0
a. Each panel, cabinet, console and other equipments in control room shall be
provided with an earthing lug. All these earthing lugs shall be properly secured to
the AC main earthing bus.
b. All circuit grounds of electronic instruments, shields and drain wires of signal
cable shall be connected to instrument ground bus which is electrically isolated
from the AC mains earthing bus. This bus shall be typically 25 mm wide and 6 mm
thick copper. The instrument grounds bus is connected to independent instrument
system ground bus through insulated wires.
c. All active barriers, if used, shall be securely grounded. The active barrier ground
wire shall be capable of carrying a maximum fault level current.
3.0
LOOP CHECKING
a. Loop checking shall be carried out by the vendor including checking the
interconnections, configuration and over all system functioning.
b. Vendors scope of work in loop checking shall include termination of field cable in
the control room through Multi Cable Transit (MCT), checking of interconnection
4.0
All the system function shall be checked thoroughly for proper functioning. The
tests shall include:
SCOPE: This specification is for the supply of 1.1 KV Lt power & control cables.
The cables shall be manufactured, tested at manufacturers works in accordance
with IS 7098(Part-II) & IS 1554 and delivered at site.
2.0
2.1
:
:
:
415 Volts + 6%
50 Hz + 3%
35 MVA at 415 Volts
2.2
2.2.1
2.2.2
Insulation:
a. The insulation shall be heat resisting type of type C PVC compound conforming
to IS 5831-1984.
b. The insulation shall be PVC applied with extrusion. The average thickness,
tolerance & application of insulation shall not be less than specifications in IS
1554 Part(I) 1988.
c. Test for thickness of insulation and sheath -
IS 1554 (Part I)
IS
IS
IS
IS
IS
IS
IS
5831-1984
5831-1984
5831-1984
5831-1984
5831-1984
5831-1984
5831-1984
7
11
12
15
10
14
IS 5831-1984
43
f.
IS 1554(Part I)1988
45
IS 1554(Part I)1988
45
h. Flammability test
IS 1554(Part I)1988
53
Acceptance Test
1.
2.
3.
4.
5.
6.
7.
8.
2.2.3
2.2.4
Armouring:
Armouring shall be GI around steel wire for YWY cable and GI steel strip for AYFY
cables and shall comply with the requirements of IS 3975-1979. It shall comply
with the requirements of non magnetic materials also. The method of armouring
shall conform to IS 1554.
2.2.5
Outer Sheath:
Outer sheath shall be of PVC compound type ST 2 as per IS: 5831-1984
3.0
The conductor shall be solid for cables of size 1.5 sq.mm to 10 sq.mm (excluding
10 sw.mm) and stranded for size 10 sq.mm and above as per IS 8130-1984. The
cross section of neutral shall be as per IS 1554 Part(I) 1988.
Cores shall be identified by different colours of PVC insulation and shall be laid as
per IS 1554 Part(I) 1988. Inner sheath, armouring and outer sheath shall be as per
IS 1554-1988.
4.0
Requirement as per
a. Test on conductor
1.
2.
3.
4.
5.
IS 8130
IS 8130
IS 8130
IS 8130
IS 1554 Part(I) 1988
& IS 3975-1979
1
2
3
5
36 to 42
4.1
Manufacturers test certificates are acceptable for all cable quantities below 500 m
length for each size.
5.0
GUARANTEE
Vendor shall give guarantee of 12 months from the date of commissioning or 18
months from the date of dispatch, whichever is earlier. During this period, if any
defect is found due to bad workmanship or wrong material used, the vendor shall
replace or repair the same free of cost.
6.0
7.0
Type Tests
Acceptance tests
Routine Test
Optional Test
:
:
:
:
review
review
review
review
2.0
PAYMENT TERMS
All payments will be made by HPCL in Indian Rupees only including for B.Q. Steel
Plates/other materials/equipment imported by the contractor. All import of
materials/equipment required as per the tender shall be done by the Contractor under
their own Import License. HPCL will not issue any Import License to the contractor.
Vendor to note that no Payment shall be released till the Design is approved by TPIA,
CCOE & HPCL. All payments shall be released after basic Design is approved.
1.0 MOUNDED STORAGE VESSELS, BQ PLATES
The payment released shall be subject to following conditions :
A.
The value of the item for Design & Drawings approval from TPIA,HPCL and CCOE
will be limited to 5% of the total value for mounded storage vessels(mechanical)
part of the order.
i. 90% of the payment for design and drawings subject to a maximum of 5% of
the total PO value will be made on completion of design, preparation of
fabrication/construction drawings, obtaining approval of TPIA & HPCL and
obtaining approval of CCOE subject to submission of BG for an equal mount.
Ii. Balance 10% will be paid after the completion of the total work and handing
over of the facility.
Iii. BG shall be releases after completion of the total work and handing over of the
facility.
B.
BQ STEEL PLATES
1
70% of the quoted item rate or 70 % suppliers invoiced rate, which ever
is lower, will be paid on submission of shipping documents for BQ Plates
as per the specifications, against a Bank guarantee for an equal amount
along with the third party inspection clearance certificates, on pro-rata
basis.
30% of the quoted item rate or suppliers invoiced rate, which ever is
lower, will be paid on delivery and identification of the plates by the TPIA
at vendors works.
The difference between the quoted rate and the payment made against
supply of steel plates shall be released along with the progressive bills for
fabrication payment as per schedule of fabrication payment.
FABRICATION
All payments will be released on pro rata basis against submission of BG for an
equal amount of the invoice amount along with the third party inspection
clearance certificates.
30% of the item rate will be paid on Rolling of the shells, completion of L &
C Seam welding, dish end fabrication and Radiography at site on pro-rata
basis.
20% of the item rate will be paid on completion of psot weld heat
treatment, completion of hydro testing, erection of accessories and
submission of dispatch documents.
Balance 20% of the item rate will be paid on receipt of vessel at site,
erection in position, pressure vessel complete in all respects and issuance
of Certificate of Control by TPIA. The BG under A,B & C above will be
returned on submission of the certificate of control.
40% of the item rate will be paid on supply of material to site on pro-rata
basis.
60% of the item rates will be paid on completion of the coating as per
specifications and clearance by TPIA
40% of the item rate will be paid on supply of material to site on pro-rata
basis.
70% of the item rate on supply of equipment to site along with third party
inspection reports.
90% of item rate will be paid upon approval of TPIA for dispatch and
receipt of the equipment at site
10% of item rate will be paid upon erection, testing and commissioning.
60% of the item rates will be paid on receipt at site of all required pipes,
elbows, flanges, tees, blinds required for the piping along with TPIA
approvals / release notes for all these items.
2.
30% of the item rate on pro rata basis will be released upon completion of
fabrication, welding, inspection, hydro testing and painting.
3
I
10% of item rate will be paid after completion of the total work and
handing over the mounded bullets.
10% of item rate will be paid upon erection, testing and commissioning.
CABLING
1
60% of the item rates will be paid on receipt at site of all required quantities
of cable, cable glands, lugs, FLP push button stations along with TPIA
approvals / release notes for all these items.
2.
30% of the item rate on pro rata basis will be released upon completion of
cable laying, fixing of glands, termination at both ends, loop checking and
testing.
NOTE:
AGAINST ALL THE ABOVE PAYMENTS NECESSARY STATUTORY DEDUCTIONS WILL BE
EFFECTED AND 10% RETENTION MONEY WILL BE WITHHELD.
ALTERNATIVELY THE PARTY CAN SUBMIT A BANK GUARANTEE FOR 10% OF THE
ORDER VALUE, BEFORE RAISING ANY BILLS, IN WHICH CASE THE 10% DEDUCTION
TOWARDS RETENTION MONEY WILL NOT BE EFFECTED FROM THE RUNNING BILLS.
All duties, taxes & statutory levies including works Contract Sales Tax are to be
included in the Basic Price for each item.
3.2
The Foreign Exchange rates prevailing on the date of due date of this tender
enquiry will be considered for the purpose of price calculations for the imported
BQ plates.
The bidder shall mention in the tender Unpriced & Priced Bids the foreign
currency considered by him. The tenderer shall also give a break-up of the foreign
exchange component involved in his quoted rates for item no. 4 of Bill of quantities
.
3.3
The tenderer is required to mention the existing rates of Customs Duty (along with
any surcharge, etc.) as presently applicable. The tenderer shall specify the heading
and sub-heading of the Tariff manual under which the steel plates are falling. The
tenderer may note that all duties are to be considered assuming that concessional
project duties are not applicable to HPCL in the present case. The tenderer is
required to mention the relevant tariff rate for customs Duty in the unpriced and
priced copy of the Price Bid attached at the end of the tender document.
3.4
A)
Any variation due to upward revision in the rate of Customs Duty (as specified in
Para 3 above and foreign exchange ( as specified in para 2 above) upto the date of
import receipt in India (not later that 4 months from the date of LOI) will be
reimbursed by HPCL. No interest shall be paid on any variation. Variation on
account on rates of R.E. and C.D., shall be payable, after the receipt of BQ steel
plates at our site, duly supported with third party inspection certificate meeting
tendered technical specifications.
B)
Tenderer will have to submit proof of earlier and existing rates, under the same
tariff head for claiming variation towards Customs Duty. Similarly, for claiming the
variation towards foreign exchange, actual bank debit or letter of credit document
D)
E)
4.
WATER & POWER: Water & Power shall be arranged by the Contractor at no extra
cost. HPCL will not provide the same.
5.
DELIVERY PERIOD: 20 (Twenty) Weeks from the date of issue of LOI or advise to
start the work by Site/ Ch Manager-E&P,LPG,SZ, Chennai, whichever is later.
6.
Site will be handed on AS IS WHERE IS BASIS for the execution of this job. HPCL
will not provide any infrastructure to the contractor at site.
7.
no
variation
For details of Liquidated damages Clause No.10 of the General Terms and
Conditions shall be referred.